WHEEL AND TIRE MAINTENANCE 13-1

STEERING SYSTEM MAINTENANCE 14-1

FRAME MAINTENANCE 15-1

SPRINGS AND SHOCKS MAINTENANCE 16-1

CAB AND BODY MAINTENANCE 17-1

MATERIAL HANDLING CRANE, SELF-RECOVERY WINCH

AND LOAD HANDLING SYSTEM MAINTENANCE 18-1

ACCESSORY ITEMS MAINTENANCE 19-1

HYDRAULIC SYSTEM MAINTENANCE 20-1

SPECIAL PURPOSE KITS MAINTENANCE 21-1

ARMAMENT MAINTENANCE 22-1

GAGES (NON-ELECTRICAL) MAINTENANCE 23-1

CHEMICAL, BIOLOGICAL, RADIOLOGICAL (CBR)

MAINTENANCE 24-1

REFERENCES A-1

MAINTENANCE ALLOCATION CHART B-1

EXPENDABLE SUPPLIES AND MATERIALS C-1

MANUFACTURED ITEMS D-1

TORQUE LIMITS E-1

MANDATORY REPLACEMENT PARTS F-1

DISTRIBUTION RESTRICTION TOOL IDENTIFICATION LIST G-1

Approved for public release;

distribution is unlimited.

TM 9-2320-364-20-5

TECHNICAL MANUAL

UNIT MAINTENANCE

VOLUME V

PALLETIZED LOAD

SYSTEM

MODEL M1074/M1075

NSN 2320-01-304-2277

NSN 2320-01-304-2278

HEADQUARTERS, DEPARTMENT OF THE ARMY

AUGUST 1999

TM 9-2320-364-20-5

 a

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

Radiator, radiator cap, coolant, and hoses are very hot and pressurized during truck operation. 

Let radiator cool before checking hoses. Failure to do so may result in serious burns to 

personnel.

Use extreme care when removing the radiator pressure cap. Sudden release of pressure can

cause a steam flash which could seriously injure personnel. Slowly loosen cap to the first stop 

to relieve pressure before removing cap completely. After opening, securely tighten cap.

Use a clean, thick waste cloth or like material to remove radiator pressure cap. Avoid using

gloves. If hot water soaks through gloves, personnel could be burned.

Apply truck brakes and chock wheels before any maintenance tasks are performed. Otherwise

serious injury to personnel could result.

Never use fuel to clean parts. Fuel is highly flammable. Serious personal injury could result if

fuel ignites during cleaning.
TM 9-2320-364-20-5

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Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc).

Failure to comply may result in injury to personnel.

Steam cleaning creates hazardous noise levels and severe burn potential. Eye, skin, and ear

protection is required. Failure to comply may result in injury to personnel.

Solvents used with a spray gun must be used in a spray booth with filter. Face shield must be

used by personnel operating spray gun. Failure to comply may result in injury to personnel.

On direct contact, uncured silicone sealant irritates eyes. In case of contact, flush eyes with

water and seek medical attention. In case of skin contact, wipe off and flush with water.

Do not drain engine oil while engine is hot. Severe injury to personnel may result.

Ensure engine is cool before performing this task or injury to personnel may result.

Use care when removing springs. Springs are under tension and can act as projectiles when

released and could cause injury to personnel.

Use care when installing springs. Springs are under tension and can act as projectiles when

released and could cause injury to personnel.
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Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and

are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use 

in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, 

wash immediately with soap and water.

Fuel is very flammable and can explode easily. To avoid serious injury or death, keep fuel away

from open fire and keep fire extinguisher within easy reach when working with fuel. Do not 

work on fuel system when engine is hot. Fuel can be ignited by hot engine.

Do not remove the radiator cap when the engine is hot; steam and hot coolant can escape and

burn personnel.

After Nuclear, Biological, or Chemical (NBC) exposure of truck, all air filters shall be handled

with extreme caution. Unprotected personnel may experience injury or death if residual toxic

agents or radioactive material are present. If truck is exposed to chemical or biological agents,

servicing personnel shall wear protective mask, hood, protective overgarments, and chemical

protective gloves and boots in accordance with FM 3-4. All contaminated air filters shall be

placed in double-lined plastic bags and moved swiftly to a segregation area away from the

worksite. The same procedure applies for radioactive dust contamination. The Company NBC

team should measure radiation prior to filter removal to determine extent of safety procedures

required per the NBC Annex to the unit Standard Operating Procedures (SOP). The segregation

area in which the contaminated air filters are temporarily stored shall be marked with

appropriate NBC placards. Final disposal of contaminated air filters shall be in accordance with

local SOP. Decontamination operation shall be in accordance with FM 3-5 and local SOP.

Brake drum can get very hot during vehicle operation. Place hand near drum to check for

excessive heat, but do not touch. Failure to comply may result in injury to personnel.

Use extreme care when removing coolant system pressure tester. Sudden release of pressure

can cause injury to personnel.
TM 9-2320-364-20-5

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Fuel is slippery and can cause falls. To avoid injury, wipe up spilled fuel with rags.

Starting fluid is toxic and highly flammable. Container is pressurized. NEVER heat container

and NEVER discharge starting fluid in confined areas or near open flame. Severe injury to 

personnel may result.

Allow engine to cool before performing maintenance on the muffler, exhaust pipe, exhaust

manifold or turbocharger. If necessary, use insulated pads and gloves.

Muffler weighs 152 lbs (69 kg). Attach suitable lifting device prior to removal to prevent

possible injury to personnel.

Ensure this task is done only when muffler is cool. Performing this task on a warm or hot

muffler may result in severe burning to personnel.

Use extreme care when removing coolant system pressure tester. Sudden release of pressure

can cause injury to personnel.

Excess coolant may splash out upon removal of tube from hump hose. Ensure proper eye

protection is worn to prevent possible injury to personnel.

Cooling assembly weighs 925 lbs (420 kg). Attach suitable lifting device for removal and

properly support cooling assembly to prevent possible injury to personnel.
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Ensure all personnel stay clear of radiator while engine is running. Air in radiator will be

released which may cause hot coolant to spray out and cause injury or death to personnel.

Engine cover assembly weighs 55 lbs (25 kg). Use an assistant to help remove engine cover

assembly or injury to personnel may result.

Radiator assembly weighs 575 lbs (261 kg). Do not stand directly under radiator assembly or

injury to personnel may result.

Ensure grille assembly is fully supported by lifting device prior to removal of screws.

Failure to comply may result in severe injury to personnel.

Adhesive causes immediate bonding on contact with eyes, skin, or clothing and also gives off

harmful vapors. Wear protective goggles and use in well-ventilated area. If adhesive gets in 

eyes, try to keep eyes open; flush eyes with water for 15 minutes and get immediate medical

attention.

Remove all jewelry such as rings, dog tags, bracelets, etc. If jewelry or tools contact positive

electrical circuits, a direct short may result. Damage to equipment, injury or death to 

personnel may occur.

Starter weighs 73 lbs. (33 kg). Attach suitable lifting device prior to removal to prevent

possible injury to personnel.
TM 9-2320-364-20-5

f 

Starter weighs 73 lbs. (33 kg). Attach suitable lifting device prior to installation to prevent

possible injury to personnel.

Use care when removing snap and retaining rings. Snap and retaining rings are under spring

tension and can act as projectiles when released and could cause severe eye injury.

Use care when installing snap and retaining rings. Snap and retaining rings are under spring

tension and can act as projectiles when released and could cause severe eye injury.

Diesel fuel is flammable. Do not perform this procedure near fire, flame, or sparks. Injury or

death to personnel could result.

Do not remove screws securing fan brace. Removing screws will cause fan brace to drop

and may result in severe injury or death to personnel.

Do not start engine or move truck when anyone is working on or under vehicle. Severe

injury or death to personnel could result.

Upon removal of all wires and cables, ensure no contact is made with battery terminals or

other wires and cables. Strap wires and cables away from battery terminals and other wires

and cables as required to prevent damage to parts, personal injury, or death.

Ensure that exhaust pipe and turbo charger pipe connections are free from soot or debris.

Failure to comply may result in exhaust leak and injury or death to personnel.
TM 9-2320-364-20-5

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Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and rubber gloves,

and do not smoke when performing maintenance on batteries. Injury will result if acid 

contacts skin or eyes. Wear rubber apron to prevent clothing being damaged.

Be careful not to short out battery terminals. Do not smoke or use open flame near batteries.

Batteries may explode from a spark. Battery acid is harmful to skin and eyes.

Wear safety goggles and acid-proof gloves when battery cover must be removed or when adding

electrolyte.

Avoid electrolyte contact with skin, eyes, or clothing. If battery electrolyte spills, take

immediate action to stop burning effects:

- External: Immediately flush with cold running water to remove all acid.

- Eyes: Flush with cold water for at least 15 minutes. Seek immediate medical attention.

- Internal: Drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or

vegetable oil. Seek immediate medical attention.

- Clothing or Vehicle: Wash at once with cold water. Neutralize with baking soda or household

ammonia solution.

Injury will result if acid contacts skin or eyes. Wear rubber apron to prevent clothing being

damaged.

Corrosion inhibitor contains alkali. Do not get in eyes; wear goggles/safety glasses when using.

Avoid contact with skin. In case of contact, immediately wash area with soap and water. If 

eyes are contacted, flush eyes with large amounts of water for at least 15 minutes and get 

immediate medical attention.
TM 9-2320-364-20-5

h 

Do not allow personnel to perform maintenance directly under boom or mast. Failure to

follow proper procedures could cause serious injury or death.

22 to 28 vdc are always present on wire 1431 at the ENGINE switch. Remove all jewelry

such as rings, dog tags, bracelets, etc. If jewelry or tools contact positive electrical circuits, a

direct short may result. Damage to equipment, injury or death to personnel may occur.

22 to 28 vdc are always present on wire 1281 and DUVAC connectors. Remove all jewelry

such as rings, dog tags, bracelets, etc. If jewelry or tools contact positive electrical circuits, a

direct short may result. Damage to equipment, injury or death to personnel may occur.

22 to 28 vdc are always present on wire 1139 at starter solenoid. Remove all jewelry such as

rings, dog tags, bracelets, etc. If jewelry or tools contact positive electrical circuits, a direct

short may result. Damage to equipment, injury or death to personnel may occur.

Transmission oil will be extremely hot when drained. Do not come in contact with hot oil to

avoid severe burns. If burned with hot oil, seek medical attention immediately.

Ensure there are no personnel in front of truck when placing it into drive. Failure to do so

may result in injury or death to personnel.

Ensure transmission oil and filter are cool prior to removal. Failure to comply may result in

injury to personnel.

Wear safety goggles when performing tests on valves. Failure to do so may result in serious

eye injury due to high pressure air.
TM 9-2320-364-20-5

 i

Fuel is very flammable and can explode easily. To avoid serious injury or death, keep fuel away

from open fire and keep fire extinguisher within easy reach when working with fuel. Do not

work on fuel system when engine is hot. Fuel can be ignited by hot engine.

Do not remove the radiator cap when the engine is hot; steam and hot coolant can escape and burn

personnel.

Driveshafts can weigh up to 100 lbs (45 kg), obtain aid from an assistant to prevent possible

injury to personnel.

Fuel is very flammable and can explode easily. To avoid serious injury or death keep flame

away from fuel and keep fire extinguisher within easy reach.

Use jackstands to support axle weight. Failure to comply may result in injury to personnel.

Brake shoes may be covered with dust. Breathing this dust may be harmful to your health. Do

not use compressed air to clean brake shoes. Wear a filter mask approved for use against 

brake dust. Failure to comply may result in injury or death to personnel.

Use care when removing brake spring. Spring is under tension and can act as a projectile when

released and could cause injury to personnel.

Use care when installing brake spring. Spring is under tension and can act as a projectile when

released and could cause injury to personnel.
TM 9-2320-364-20-5

j 

22 to 28 vdc are always present at DUVAC connectors. Care must be exercised when

removing the DUVAC cover. Remove all jewelry such as rings, dog tags, bracelets, etc. If

jewelry or tools contact positive electrical circuitc, a direct short may result. Damage to

equipment, injury or death to personnel may occur.

Spring in air chamber is very powerful and is under tension. Failure to cage air chamber before

removal will release tension of spring abruptly and could result in injury or death to personnel.

Air reservoir will fall when screws are removed. Support air reservoir prior to removing screws

to prevent injury to personnel.

Do not touch hot exhaust system with bare hands; injury to personnel will result.

Allow engine to cool before performing troubleshooting maintenance. If necessary use

insulated pads and gloves. Hot engine components will burn and cause injury to personnel.

Terminal 1 and terminal 2 at DUVAC controller are electrically hot all of the time. Ensure

bracket does not contact either terminal. Damage to equipment, injury or death to personnel

may occur.

Terminal 1 and terminal 2 at DUVAC controller are electrically hot all of the time. Ensure

DUVAC cover or bracket does not contact either terminal. Damage to equipment, injury or

death to personnel may occur.

Inner wheel weighs 105 lbs (48 kg). Attach suitable lifting device prior to moving rim to

prevent possible injury to personnel.
TM 9-2320-364-20-5

 k

Ensure all personnel keep hands and fingers out from between tire and bead lock. Failure to

comply may result in injury to personnel.

Alternator is capable of producing over 40 vdc. Be careful when taking a voltage reading

not to get shocked.

High pressure hydraulics [oil under 3,700 psi (25,512 kPa) pressure] operate this equipment.

Refer to vehicle operator and maintenance manuals for hydraulic oil pressure. Never disconnect

any hydraulic line or fittings without first dropping pressure to zero. High pressure oil stream

can pierce body and cause severe injury to personnel.

.

Ensure all personnel wear proper eye protection. Do not stand directly in front of valve stem

when draining air from tire. Tire is under extreme air pressure. Failure to comply may result 

in injury to personnel.

Prolonged contact with lubricating oil (MIL-L-2104) may cause a skin rash. Skin and clothing

that come in contact with lubricating oil should be thoroughly washed immediately. Saturated

clothing should be removed immediately. Areas in which lubricating oil is used should be

well-ventilated to keep fumes to a minimum.

Tie-rod end may unexpectedly pop-up when pressure is applied with hydraulic jack. Keep

hands and face clear of tie-rod end. Failure to comply may result in severe injury to

personnel.

Skid plate weighs 130 lbs (59 kg). Attach suitable lifting device prior to removal to prevent

injury to personnel.
TM 9-2320-364-20-5

l 

Skid plate structure weighs 95 lbs (43 kg). Attach suitable lifting device prior to removal to

prevent injury to personnel.

Skid plate crossmember weighs 55 lbs (25 kg). Attach suitable lifting device prior to removal to

prevent possible injury to personnel.

Right hand and left hand extension assemblies weigh 110 lb (50 kg) each. Use the aid of an

assistant when lifting to prevent injury to personnel.

Crossover tube weighs 100 lbs (45 kg). Attach a suitable lifting device prior to removal to

prevent possible injury to personnel.

Each hard lift bracket weighs 67 lbs (30 kg). Attach a suitable lifting device prior to removal to

prevent possible injury to personnel.

Self-guided coupler weighs 100 lbs (45 kg). Attach suitable lifting device prior to removal

to prevent possible injury to personnel.

The exhaust pipe and muffler can become very hot during vehicle operation. Be careful not to

touch these parts with bare hands, or allow body to come in contact with pipe or muffler. 

Exhaust system parts can become hot enough to cause serious burns.

Support hoist extension before removing retaining pin or injury to personnel may occur.
TM 9-2320-364-20-5

 m

Tire carrier weighs 145 lbs (66 kg). Attach suitable lifting device prior to removal to prevent

possible injury to personnel.

Wire rope can become frayed or contain broken wires. Wear heavy leather-palmed work

gloves when handling wire rope. Frayed or broken wires can cause injury to personnel.

Never let moving wire rope slide through hands, even when wearing gloves. A broken wire

could cut through glove and can cause injury to personnel.

Cab door weighs 100 lbs (45 kg). Support with suitable lifting device to avoid injury to

personnel.

Do not let window fall. Broken glass may cause serious injury to personnel.

Platform assembly weighs 62 lbs (28 kg). Attach suitable lifting device prior to removal to

prevent possible injury to personnel.

Always wear proper eye protection and protective clothing when handling glass. Failure to

comply may result in injury to personnel.

Seat assembly weighs 55 lbs (25 kg). Attach suitable lifting device to prevent possible

injury to personnel.
TM 9-2320-364-20-5

n 

Box assembly weighs 92 lbs (42 kg). Ensure box assembly is properly supported to prevent

possible injury to personnel.

Wear heavy gloves when handling crane cable. Never let cable run through hands; frayed

cables can cut.

The crane hydraulic system operates at oil pressures up to 3,100 psi (21,375 kPa). Never

disconnect any hydraulic line or fitting without first dropping the pressure to zero. Failure to

comply may result in serious injury or death to personnel.

Self-recovery winch weighs 645 lbs (292 kg). Attach suitable lifting device to prevent

possible injury to personnel.

Front tension guide weighs 60 lbs (27 kg). Use an assistant to prevent possible injury to

personnel.

Leave top front screw installed in frame to prevent spacer from falling. Failure to comply may

result in injury to personnel.

Front guide assembly weighs 75 lbs (34 kg). Use an assistant to prevent injury to personnel.

Position top front screw in frame to hold spacer in place. Failure to comply may result in

injury to personnel.
TM 9-2320-364-20-5

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Rear tension guide weighs 50 lbs (23 kg). Use an assistant to prevent injury to personnel.

Rear guide assembly weighs 65 lbs (29 kg). Use an assistant to prevent possible injury to

personnel.

Rear roller assembly weighs 375 lbs (170 kg). Attach suitable lifting device prior to removal to

prevent possible injury to personnel.

Do not remove heater hoses when engine is hot; steam and hot coolant can escape and burn

personnel.

Use clean wiping rags or like material to remove heater hoses. Avoid using gloves. If hot

water soaks through gloves, personnel could be burned.

Coolant is slippery and can cause falls and injury. Clean up spilled coolant immediately.

Allow engine to cool prior to removal of heater core to prevent burns and injury to personnel.

Use caution when removing hoses to prevent getting antifreeze in eyes or mouth, if antifreeze

does get in eyes or mouth, seek medical attention immediately.

Extreme care should be taken when removing heater hoses if water temperature gage reads

above 180 degrees F (82 degrees C). Contact by steam or hot coolant may result in injury or

death to personnel.
TM 9-2320-364-20-5

p 

Allow engine to cool prior to removal of valve to prevent burns and possible injury to

personnel.

Ensure engine is cool before performing this task or severe burns from hot hydraulic fluid may

result.

The main hydraulic system operates at oil pressures up to 3,675 psi (25,339 kPa). Never

disconnect any hydraulic line, fitting or component without first dropping pressure to zero.

Failure to comply may result in serious injury or death to personnel.

Use extreme care when loosening filler cap. Sudden release of pressure could seriously injure

personnel. Slowly loosen cap to relieve pressure and ensure proper eye protection is worn.

Hydraulic reservoir weighs 120 lbs (54 kg). The aid of an assistant is required to prevent

possible injury to personnel.

Battery weighs 75 lbs (34 kg). Remove battery only with the aid of an assistant to prevent

possible injury to personnel.

Battery weighs 75 lbs (34 kg). Install battery only with the aid of an assistant to prevent

possible injury to personnel.

Battery box weighs 75 lbs (34 kg). Use the aid of an assistant to prevent possible injury to

personnel.
TM 9-2320-364-20-5

 q

Sharp edges of exhaust pipe could cause injury to personnel.

Coolant may run out of water jacket when turned. Wear eye protection or injury to

personnel may result.

High pressure hydraulics [oil under 3,100 psi (21,374 kPa) pressure] operate this equipment.

Refer to vehicle operator and maintenance manuals for hydraulic oil pressure. Never

disconnect any hydraulic line or fittings without first dropping pressure to zero. A high

pressure oil stream can pierce body and cause severe injury to personnel.

Machine gun ring weighs 295 lbs (134 kg). Attach suitable lifting device to prevent injury to

personnel.

Machine gun ring front support weighs 55 lbs (25 kg). Attach suitable lifting device to

prevent injury to personnel.

Circuit breakers CB5, CB6, CB12, CB20, CB22, CB23 and relays R3, R13 - R19, R26, R28,

R32, R33 are always electrically hot and can cause severe injury to personnel. Care must be

exercised when working under the electrical circuit board cover.

Ensure equipment will not move while repairing or inspecting it. For trailers, “red tag” the

hitch, and block or chock wheels or tracks. For powered equipment, block or chock wheels

or tracks, and “red tag” the starter. Prevent a “quick fix” from becoming a quick injury.

When adjustment or service requires a running engine, two personnel will be used; one at

controls and one at service point. This helps prevent accidental movement of controls.
TM 9-2320-364-20-5

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Wires 1866 and 1867 have 12 vdc at all times direct from batteries. Care must be exercised

when working with these wires to avoid injury to personnel.

Ensure all personnel are clear of rear of truck before shifting into R (reverse). Failure to do

so might result in injury or death to personnel.

Circuit breakers and relays are always electrically hot and can cause severe injury to

personnel. Care must be exercised when working under the electrical circuit board cover.

Ether is toxic and highly flammable. Container is pressurized. Never heat container and

never discharge ether into confined areas or near open flame. Severe injury to personnel

may result.

Do not place any part of body in area of fan operation. Failure to do so will result in injury

or death to personnel.

10 to 14 vdc are always present at terminals E and F of connector MC7.

Before inflating or deflating, stand out of the trajectory area or personal injury or death may

result.

Hot transmission oil can cause severe burns and injury to personnel. Transmission should be

allowed to cool before oil is drained.
TM 9-2320-364-20-5

 s

Wear safety goggles when performing leakage tests on valves. Failure to do so may result in

serious eye injury due to high pressure air.

If air lines are under high pressure when they are disconnected, they can whip around and

cause injury to personnel. Caution should be exercised when loosening or disconnecting air

line fittings.

Exercise extreme caution when working around wheels or under truck while engine is

operating. Movement of truck may cause injury or death to personnel.

Keep clear of equipment when equipment is being raised or lowered. Equipment may fall

and cause serious injury or death to personnel.

Never crawl under equipment when performing maintenance unless equipment is securely

blocked. Equipment may fall and cause serious injury or death to personnel.

Do not work on any item supported only by lift jacks or hoist. Always use blocks or proper

stands to support the item prior to any work. Equipment may fall and cause injury or death

to personnel.

Ensure transmission is cool before proceeding. Failure to comply may result in injury to

personnel.

Keep hands and arms away from fan blade and drive while engine is running, or serious injury

to personnel will result.
TM 9-2320-364-20-5

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Maintain adequate distance from moving steering parts or serious injury to personnel may

result.

Do not stand between wheels when engine is operating. Movement of vehicle can cause injury

or death to personnel.

Truck must be on level ground and wheels must be chocked before parking brake is released.

Otherwise, truck may roll and cause injury to personnel.

Do not use retread tires on vehicles equipped with a Central Tire Inflation System (CTIS).

Use only the tires that are specified in the Repair Parts and Special Tools List (RPSTL).

Failure to comply may result in tire failure and loss of vehicle control.

Ensure transfer case is cool before proceeding. Failure to comply may result in injury to

personnel.

Failure to place wheel/tire assembly in safety cage prior to initial inflation could result in

serious injury or death to personnel.

When a wheel/tire is in a restraining device, do not lean any part of body or equipment on 

or against the restraining device, or injury or death could result.

Stand clear of trajectory area during deflation or personal injury or death may result.
TM 9-2320-364-20-5

 u

Always completely deflate tire by removing valve core from valve stem before attempting

demounting operation. After air has finished exhausting from valve stem, carefully run a

piece of wire through valve stem to ensure it is not plugged and tire is completely deflated.

Failure to comply may result in injury to personnel.

Wheel/tire assembly must be deflated in a safety cage or personal injury or death may result.

Keep hands clear of studs and outer face of wheel to prevent injury to personnel.

Wheel/tire assembly weighs 523 lbs (237 kg). Attach suitable lifting device prior to 

moving to prevent possible injury to personnel.

Stay out of the trajectory as indicated by the area shown. Under some circumstances, the

trajectory may deviate from its expected path. Injury or death to personnel may result.

Container lock could drop suddenly if not supported. Failure to comply may result in injury

to personnel.

Slider weighs 142 lbs (64 kg). Attach suitable lifting device to prevent possible injury to

personnel.

Right front support bracket weighs 98 lbs (44 kg). Attach suitable lifting device to prevent

possible injury to personnel.
TM 9-2320-364-20-5

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Left front support bracket weighs 98 lbs (44 kg). Attach suitable lifting device to prevent

possible injury to personnel.

Front support assembly weighs 660 lbs (299 kg). Attach suitable lifting device to prevent

possible injury to personnel.

Front crossmember assembly weighs approximately 500 lbs (227 kg). Attach suitable lifting

device to prevent possible injury to personnel.

Stow cone weldment weighs approximately 225 lbs (102 kg). Attach suitable lifting device

to prevent possible injury to personnel.

Rear guide assembly weighs 70 lbs (32 kg). Attach suitable lifting device to prevent

possible injury to personnel.

Slide arm weighs 65 lbs (29 kg). Attach suitable lifting device to prevent possible injury to

personnel.

Lifting frame weighs 1600 lbs (726 kg). Attach suitable lifting device to prevent possible

injury to personnel.

Stow weldment weighs 410 lbs (186 kg). Attach suitable lifting device to prevent possible

injury to personnel.
TM 9-2320-364-20-5

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Rear roller bracket weighs 150 lbs (68 kg). When removing one rear roller bracket, ensure

remaining rear roller bracket is supported. Attach suitable lifting device to prevent possible

injury to personnel.

Arm assembly weighs 240 lbs (109 kg). Attach suitable lifting device to prevent possible

injury to personnel.

Right strut bracket assembly weighs 80 lbs (36 kg). Attach suitable lifting device to prevent

possible injury to personnel.

Alternator weighs 75 lbs (34 kg). Use the aid of an assistant to prevent possible injury to

personnel.

Starter weighs 73 lbs (33 kg). Attach suitable lifting device prior to installation to prevent

possible injury to personnel.

Ensure brake drum is not pulled back more than approximately two inches (5 cm). Failure to

comply may result in injury or death to personnel.

Most circuit breakers are always electrically hot and can cause severe injury to personnel. Care

must be exercised when working under the ECB cover.

Tip of removal tool is very sharp. Use caution when using tool. Failure to comply may result in

injury to personnel.
TM 9-2320-364-20-5

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Stand clear of tires while turning them. Failure to do so may result in injury or death to personnel

Never inflate the wheel/tire assembly unless all ten outer wheel nuts have been properly torqued

or personal injury could result.

Brake drum weighs 132 lbs (60 kg). Attach suitable lifting device to prevent possible injury to

personnel.

Axle’s No. 1 and No. 2 brake drums may swing out during removal. Use the aid of an assistant to

support lifting device. Failure to comply may result in injury to personnel.

Keep hands clear of studs and outer face of axles to prevent injury to personnel.

Stand clear of tires while turning. Failure to do so may result in injury or death to personnel.

Sharp edges of exhaust pipe could cause injury to personnel.

Do not remove hoses when cooling system is hot; steam and hot coolant can escape and burn

personnel.
TM 9-2320-364-20-5

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The hydraulic system operates at high pressures. Never disconnect any hydraulic line or

fitting without first dropping pressure to zero. Failure to comply may result in serious injury

or death to personnel.

CARC paint contains isocyanate (HDI) which is highly irritating to skin and respiratory

system. High concentrations of HDI can produce symptoms of itching and reddening of

skin, a burning sensation in throat and nose and watering of the eyes. In extreme

concentrations, HDI can cause cough, shortness of breath, pain during respiration, increased

sputum production, and chest tightness. The following precautions must be taken whenever

using CARC paint:

• ALWAYS use air line respirators when using CARC paint unless air sampling shows

exposure to be below standards. Use chemical cartridge respirator if air sampling is below

standards.

• DO NOT let skin or eyes come in contact with CARC paint. Always wear protective

equipment (gloves, ventilation mask, safety goggles, etc.).

• DO NOT use CARC paint without adequate ventilation.

• NEVER weld or cut CARC-coated materials.

• DO NOT grind or sand painted equipment without high-efficiency air purifying respirators 

in use.

• BE AWARE of CARC paint exposure symptoms; symptoms can occur a few days after 

initial exposure. Seek medical help immediately if symptoms are detected.

Horizontal roller weighs 75 lbs (34 kg). Attach suitable lifting device prior to removal to

prevent possible injury to personnel.

Do not put fingers in between boom sections when removing wear pads. Use a screwdriver

or similar tool to remove wear pads. Failure to comply may result in injury to personnel.

Do not put fingers in between boom sections when installing wear pads. Use a screwdriver

or similar tool. Failure to comply may result in injury to personnel.
TM 9-2320-364-20-5

z 

Do not inhale fumes; could cause severe injury or death.

Do not over-tighten clamp during installation. Accumulator is filled with compressed gas, and

a change in pressure could cause crane to malfunction. Failure to complay may result in

injury or death to personnel.

Wire cable assembly can become frayed or contain broken wires. Wear heavy leatherpalmed work gloves when handling wire cable assembly. Frayed or broken wires can cause

injury to personnel.

Never let moving wire cable assembly slide through hands, even when wearing gloves. A

broken wire could cut through glove and cause injury to personnel.

Air cleaner assembly can weigh up to 100 lbs (45 kg). Ensure air cleaner assembly is

properly supported during removal. Failure to comply may result in injury to personnel.

Ensure air cleaner assembly is properly supported. Failure to comply may result in injury to

personnel.

Use care when removing retaining rings. Retaining rings are under spring tension and can

act as projectiles when released and could cause severe eye injury.

Use care when installing retaining rings. Retaining rings are under spring tension and can

act as projectiles when released and could cause severe eye injury.
TM 9-2320-364-20-5

 A/(B blank)

* Zero In This Column Indicates An Original Page.

LIST OF EFFECTIVE PAGES Insert latest changed pages. Destroy superseded pages.

NOTE

The portion of the text effected by the changes is indicated by a vertical line in the outer

margins of the page. Changes to illustrations are indicated by a shadowed or screened

areas, or by miniature pointing hands.

Dates of issue for original and changed pages are:

Original . . . . . . 0 1 August 1999 . . . 

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 1124 CONSISTING OF THE FOLLOWING:

Page 

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*Change

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a - z . . . . . . . . . . . . . . . . . . . . . . . . . . . 0

A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0

B Blank . . . . . . . . . . . . . . . . . . . . . . 0

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19-80 Blank . . . . . . . . . . . . . . . . . . 0

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G-4 Blank . . . . . . . . . . . . . . . . . . . . 0

INDEX-1 - INDEX-15 . . . . . . . 0

INDEX-16 Blank . . . . . . . . . . . . . 0

TM 9-2320-364-20-5

 i

TECHNICAL MANUAL HEADQUARTERS

DEPARTMENT OF THE ARMY

No. 9-2320-364-20 Washington, D.C. 01 August 1999

Unit Maintenance Manual

PALLETIZED LOAD SYSTEM

MODEL M1074/M1075

NSN 2320-01-304-2277

NSN 2320-01-304-2278

Current as of 01 August 1999

REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures,

please let us know. Submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms),

through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is

http://aeps.ria.army.mil. If you need a password, scroll down and click on “ACCESS REQUEST FORM.” The DA

Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. Fill out the form and click on

SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the

DA Form 2028 program. You may also mail, fax or email your letter, DA Form 2028, or DA Form 2028-2, located

at the back of this manual direct to: Commander, U.S. Army Tank-automotive and Armaments Command, ATTN:

AMSTA-AC-NML, Rock Island, IL 61299-7630. The email address is amsta-ac-nml@ria.army.mil. The fax

number is DSN 793-0726 or Commercial (309) 782-0726. A reply will be furnished to you.

TABLE OF CONTENTS

Page

CHAPTER 13 WHEEL AND TIRE MAINTENANCE 13-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 14 STEERING SYSTEM MAINTENANCE 14-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

CHAPTER 15 FRAME MAINTENANCE 15-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

CHAPTER 16 SPRINGS AND SHOCKS MAINTENANCE 16-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

CHAPTER 17 CAB AND BODY MAINTENANCE 17-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

CHAPTER 18 MATERIAL HANDLING CRANE (MHC), SELF-RECOVERY WINCH

(SRW) AND LOAD HANDLING SYSTEM (LHS) MAINTENANCE 18-1 . . . . . . . . . . . . . . . . . . . 

CHAPTER 19 ACCESSORY ITEMS MAINTENANCE 19-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

CHAPTER 20 HYDRAULIC SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

CHAPTER 21 SPECIAL PURPOSE KITS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1

CHAPTER 22 ARMAMENT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1
TM 9-2320-364-20-5

ii

Page

CHAPTER 23 GAGES (NON–ELECTRICAL) MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1

CHAPTER 24 CHEMICAL, BIOLOGICAL, AND RADIOLOGICAL (CBR)

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-1

APPENDIXES

A REFERENCES A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

B MAINTENANCE ALLOCATION CHART B-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

C EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST C-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 

D ILLUSTRATED LIST OF MANUFACTURED ITEMS D-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

E TORQUE LIMITS E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

F MANDATORY REPLACEMENT PARTS F-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

G TOOL IDENTIFICATION LIST G-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

INDEX INDEX-1

SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCHMTC-1

Section I 145 Amp Alternator and DDEC II Engine

Section II 200 Amp Alternator and DDEC III Engine
TM 9-2320-364-20-5

 iii/(iv blank)

HOW TO USE THIS MANUAL

This manual is designed to help maintain the Model M1074/M1075 Palletized Load System (PLS) truck. Listed below

are some special features included in this manual to help locate and use the needed information:

• A front cover table of contents is provided for quick reference to chapters and sections that will be used

often.

• WARNING, CAUTION, and NOTE headings, subject headings, and other essential information are 

printed in bold type making them easier to see.

• The maintenance tasks describe what must be done to the truck before starting the task (Equipment

Condition), and what must be done to return the vehicle to operating condition after the task is finished

(Follow-On Maintenance).

• The Appendixes are located at the end of the manual. They contain a reference guide to other manuals, 

the Maintenance Allocation Chart (MAC), a list of expendable supplies and materials, and other material

for maintaining the PLS truck.

• In addition to text, there are exploded-view illustrations showing how to take a component off and put it

back on. Cleaning and inspection procedures are also included as required.

• Chapters 13 through 24 of this manual cover Unit Maintenance for each PLS truck system.

Follow these guidelines when using this manual:

• Read all WARNINGS and CAUTIONS before performing any procedure.

• The equipment conditions found in the maintenance procedures are of a general nature and the mechanic 

may be able to perform only certain steps within a procedure to accomplish the equipment condition.

TM 9-2320-364-20-5

 13-1

CHAPTER 13

WHEEL AND TIRE MAINTENANCE

Para Contents Page

13-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

13-2 Wheel/Tire Assembly Repair 13-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

13-3 Axle Brake Drum Replacement 13-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

13-4 Axles No. 1, 2 And 5 Central Tire Inflation System (CTIS) Spindle Fittings Replacement 13-17 . . . . . . . 

13-5 Axles No. 3 And 4 Central Tire Inflation System (CTIS) Spindle Fittings Replacement 13-20 . . . . . . . . . . 

13-6 Central Tire Inflation System (CTIS) Air Lines Replacement 13-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

13-7 Central Tire Inflation System (CTIS) Controller Replacement 13-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

13-8 Central Tire Inflation System (CTIS) Front Manifold Replacement 13-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

13-9 Central Tire Inflation System (CTIS) Rear Manifold Replacement 13-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

13-10 Central Tire Inflation System (CTIS) Front And Rear Manifold Repair 13-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

13-11 Central Tire Inflation System (CTIS) Wheel Valve Repair 13-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

13-12 Tire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-50

13-13 Central Tire Inflation System (CTIS) Controller Protection Kit Installation/Replacement 13-51 . . . . . . . . 

13-1. INTRODUCTION.

This chapter contains maintenance instructions for removing, replacing, installing and adjusting wheel and tire 

components as authorized by the Maintenance Allocation Chart (MAC) at the Unit Maintenance level.
TM 9-2320-364-20-5

13-2 

This task covers:

a. Disassembly c. Assembly

b. Cleaning/Inspection d. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheel and tire removed from truck,

(TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Multiplier, Torque (Item 45, Appendix G)

Repair Tool, Pneumatic Tire, Valve

(Item 56, Appendix G)

Socket Set, 3/4 in. (Item 61, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Torque (0 to 300 lb-ft [0 to 407 N.

m])

(Item 96, Appendix G)

Wrench, Torque (0 to 60 N.

m)

(Item 98, Appendix G)

Lifting Device

(Minimum Capacity 600 lbs [272 kg])

Wooden Block (Appendix D)

Materials/Parts

Lubricant, Tire and Rim (Item 53, Appendix C)

Sealing Compound (Item 74, Appendix C)

Grommet (2) (Item 72, Appendix F)

Locknut (4) (Item 122, Appendix F)

Packing, Preformed (Item 246, Appendix F)

Packing, Preformed (2) (Item 262, Appendix F)

Valve Core (Item 342, Appendix F)

13-2. WHEEL/TIRE ASSEMBLY REPAIR.

References

TM 9-2610-200-14
TM 9-2320-364-20-5

 13-3

a. Disassembly.

• Wheel/tire assembly must be deflated in a safety cage or personal injury or death may result.

• Wheel/tire assembly weighs 523 lbs (237 kg). Attach suitable lifting device prior to

moving to prevent possible injury to personnel.

NOTE

Refer to TM 9-2610-200-14 for construction of safety cage.

(1) Using lifting device, position wheel/tire assembly (1) in a safety cage.

(2) Remove valve cap (2) from valve stem (3).

• Stand clear of trajectory area during deflation or personal injury or death may result.

• High air pressure will be released from valve stem when valve core is removed. Stay clear

of valve stem after core is removed. Ensure all personnel wear suitable eye protection.

Failure to comply may result in injury to personnel.

• Always completely deflate tire by removing valve core from valve stem before attempting

demounting operation. After air has finished exhausting from valve stem, carefully run a

piece of wire through valve stem to ensure it is not plugged and tire is completely deflated.

Failure to comply may result in injury to personnel.

(3) Remove valve core (4) from valve stem (3).

Discard valve core.

(4) Remove wheel/tire assembly (1) from safety

cage and position on wooden block on flat

surface with Central Tire Inflation System

(CTIS) wheel valve assembly (5) facing up.
TM 9-2320-364-20-5

13-4 

13-2. WHEEL/TIRE ASSEMBLY REPAIR (CONT).

(5) Disconnect two valve stems (6) from fittings (7).

(6) Remove and discard two preformed packings (8) from valve stems (6).

(7) Remove twelve lug nuts (9) from studs (10).

(8) Remove CTIS wheel valve assembly (2) from outer wheel (11).

Keep hands clear of studs and outer face of wheel to prevent injury to personnel.

NOTE

A tire iron can be used to lift the outer wheel.

(9) Pry outer wheel (11) and tire (12) apart.

(10) Remove outer wheel (11) from inner wheel (13).

Wheel/tire assembly weighs 523

lbs (237 kg). Attach suitable

lifting device prior to moving to

prevent possible injury to

personnel.

(11) Attach lifting device to wheel/tire assembly (1).

(12) Raise and turn wheel/tire assembly (1) over

so inner wheel (13) center rests on wooden

block. Lower tire (12).

(13) Remove lifting device from wheel/tire assembly (1).

(14) Pry inner wheel (13) and tire (12) apart.
TM 9-2320-364-20-5

 13-5

Inner wheel weighs 105 lbs (48

kg). Attach suitable lifting 

device prior to moving rim to

prevent possible injury to 

personnel.

(15) Attach lifting device to inner wheel (13).

(16) Remove inner wheel (13) from tire (12).

(17) Remove and discard preformed packing (14)

from inner wheel (13) and cut in two.

(18) Remove two nuts (15), valve stems (6) and

grommets (16) from inner wheel (13).

Discard grommets.

NOTE

If studs are damaged, perform

Steps (19) through (25). If studs

are not damaged, perform

Steps (20) through (25).

(19) Remove damaged studs (17) from inner

wheel (13). Discard damaged studs. 13

6

16

15

17
TM 9-2320-364-20-5

13-6 

13-2. WHEEL/TIRE ASSEMBLY REPAIR (CONT).

NOTE

Mallet and tire lubricant may be

used to ease movement of bead

lock.

(20) Move bead lock (18) until locknuts (19) are

visible.

NOTE

Positioning tire against a

stationary object may ease in

removal of bead lock.

(21) Attach lifting device to tire (12) and

position tire upright at a slight angle.

(22) Remove lifting device from tire (12).

(23) Remove four locknuts (19), two plates (20)

and screws (21) from bead lock (18).

Discard locknuts.

(24) Remove one end of bead lock (18) from

tire (12).

(25) Remove the remaining section of bead lock (18) from tire (12) by “cork screwing” bead lock from tire

(12).

b. Cleaning/Inspection.

(1) Inspect tire tread for nails, glass and other injurious particles in tread.

(2) Inspect tire for irregular wear, cuts and blisters appearing on tire.

(3) Inspect bead of tire for damaged rim seal ridges.
TM 9-2320-364-20-5

 13-7

(4) Inspect complete inside surface of inner liner for imperfections, discoloration or irregular surface that may

indicate excessive heat, breaks or other fabric damage.

(5) Check rims for cracks, dents, dirt and rust.

(6) Remove rust, gummy rubber deposits, nicks and gouges in the rim bead seat surface to provide an airtight

seal with the tire bead.

(7) Remove all dirt and foreign material from inside of tire and inspect the inside of tire for damage.

(8) Clean rust and dirt from rim using a steel brush.

(9) Paint wheel asembly parts as needed to protect against rust.

(10) Replace any bent, broken, stripped or damaged studs or bolts.

c. Assembly.

• Ensure all personnel keep hands and fingers out from between tire and bead lock. Failure

to comply may result in injury to personnel.

• Do not use retread tires on vehicles equipped with a Central Tire Inflation System (CTIS).

Use only the tires that are specified in the Repair Parts and Special Tools List (RPSTL).

Failure to comply may result in tire failure and loss of vehicle control.

NOTE

• Tire lubricant may be used to ease installation of bead lock in tire.

• Curved plate is installed in same direction as curve in bead lock.

(1) Insert one end of bead lock (18) into tire (12).

(2) Insert remaining section of bead lock (18) by “cork screwing” into tire (12).
TM 9-2320-364-20-5

13-8 

13-2. WHEEL/TIRE ASSEMBLY REPAIR (CONT).

(3) Align both ends of bead lock (18) and install

two plates (20) on bead lock (18) with four

screws (21) and locknuts (19).

(4) With the aid of an assistant, position bead

lock (18) in tire (12) by rolling tire until

bead lock has centered properly.
TM 9-2320-364-20-5

 13-9

(5) Attach lifting device to tire (12) and lay tire

on wooden block.

(6) Remove lifting device from tire (12).

If wheel studs were replaced, they

must be torqued after 50 to 75

miles (80 to 120 km) of use.

Failure to comply may result in

failure of wheel studs.

NOTE

• If damaged studs were

removed, perform Step (7).

• Ensure flat edge of stud head

is positioned parallel to edge

of inner wheel.

(7) Install new stud (17) in inner wheel (13)

until base of stud is solid against back side of

rim.

Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and 

are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use 

in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, 

wash immediately with soap and water.

(8) Coat threads of two nuts (15) with sealing compound.

(9) Install two grommets (16) and valve stems (6) in inner wheel (13) with two nuts (15).
TM 9-2320-364-20-5

13-10 

13-2. WHEEL/TIRE ASSEMBLY REPAIR (CONT).

(10) Apply tire lubricant to preformed

packing (14) and install on inner wheel (13).

Inner wheel weighs 105 lbs (48

kg). Attach suitable lifting 

device prior to moving rim to

prevent possible injury to

personnel.

(11) Attach lifting device to inner wheel (13).

(12) Install inner wheel (13) in tire (12).

Wheel/tire assembly weighs 523

lbs (227 kg). Attach suitable lifting

device prior to removal to prevent

possible injury to personnel.

(13) Attach lifting device to wheel/tire assembly (1).

(14) Raise and turn wheel/tire assembly (1) over and

position inner wheel (13) on wooden block.

(15) Remove lifting device from wheel/tire

assembly (1).
TM 9-2320-364-20-5

 13-11

Keep hands clear of studs and outer face of wheel to prevent injury to personnel.

Holes in outer wheel must align with holes in inner wheel. Failure to comply may result in

damage to valve stems.

(16) Position outer wheel (11) on inner wheel (13) so that valve stems (6) are positioned through outer wheel.

NOTE

Tighten lug nuts 1/4 in. (6.4 mm) maximum at a time in sequence shown until inner wheel

and outer wheel meet.

(17) Install outer wheel (11) and CTIS wheel valve assembly (5) on studs (10) with twelve lug nuts (9). Use

tightening sequence 1 and tighten to 75 to 100 lb-ft (102 to 136 N.

m).

NOTE

Tightening sequence is performed three times.

(18) Tighten 12 lug nuts (9) in sequence 1 to 450 to 500 lb-ft (610 to 678 N.

m).

(19) Tighten 12 lug nuts (9) in sequence 2 to 450 to 500 lb-ft (610 to 678 N.

m).

(20) Tighten 12 lug nuts (9) in sequence 2 to 450 to 500 lb-ft (610 to 678 N.

m).
TM 9-2320-364-20-5

13-12 

13-2. WHEEL/TIRE ASSEMBLY REPAIR (CONT).

(21) Install two preformed packings (8) and fittings (7) on valve stems (6).

(22) Install valve core (4) in valve stem (3).

• Failure to place wheel/tire assembly in safety cage prior to initial inflation could result in

serious injury or death to personnel.

• When a wheel/tire is in a restraining device, do not lean any part of body or equipment on

or against the restraining device, or injury or death could result.

(23) Using lifting device position wheel/tire assembly (1) in safety cage.
TM 9-2320-364-20-5

 13-13

• Stay out of the trajectory as indicated by the area shown. Under some circumstances, the

trajectory may deviate from its expected path. Injury or death to personnel may result.

• Never inflate the wheel/tire assembly unless all ten outer wheel nuts have been properly

torqued or personal injury could result.

NOTE

Refer to TM 9-2610-200-14 for construction of safety cage.

(24) Inflate tire (1) to 75 psi (517 kPa) and check for leaks (TM 9-2320-364-10).

(25) Install valve cap (2) on valve stem (3).

(26) Remove wheel/tire assembly (1) from safety cage.

d. Follow-On Maintenance:

• Install tire on truck, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

13-14 

Materials/Parts

Sealing Compound (Item 73, Appendix C)

Tags, Identification (Item 88, Appendix C)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Wheel/tire assembly removed,

(TM 9-2320-364-10)

Brakes caged (Axles No. 3, 4 and 5 only),

(TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Lifting Device, Minimum Capacity 132 lbs

(60 kg)

13-3. AXLE BRAKE DRUM REPLACEMENT.

Personnel Required

Two

a. Removal.

NOTE

Axle No. 3 brake drum is shown. All brake drums are replaced the same.

(1) Remove two fittings (1) from brake drum (2).
TM 9-2320-364-20-5

 13-15

• Brake drum weighs 132 lbs 

(60 kg). Attach suitable 

lifting device to prevent

possible injury to personnel.

• Axle’s No. 1 and No. 2 brake

drums may swing out during

removal. Use the aid of an

assistant to support lifting

device. Failure to comply

may result in injury to

personnel.

• Keep hands clear of studs 

and outer face of axles to

prevent injury to personnel.

(2) Using lifting device and with the aid of an

assistant, remove brake drum (2) from wheel

hub assembly (3).

b. Installation.

Brake drum weighs 132 lbs 

(60 kg). Attach suitable lifting

device to prevent possible injury

to personnel.

NOTE

Ensure that fitting holes line up

before installing brake drum.

(1) Using lifting device and the aid of assistant,

align and install brake drum (2) on wheel

hub assembly (3).
TM 9-2320-364-20-5

13-16 

13-3. AXLE BRAKE DRUM REPLACEMENT (CONT).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(2) Coat threads of two fittings (1) with sealing

compound.

(3) Install two fittings (1) in brake drum (2).

c. Follow-On Maintenance:

• Uncage brakes, (TM 9-2320-364-10).

• If installing new brake drum, adjust brakes, (Para 12-3).

• Install wheel/tire assembly, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 13-17

Materials/Parts

Cable Ties (Item 26, Appendix C)

Sealing Compound (Item 72, Appendix C)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Materials/Parts - Continued

Tags, Identification (Item 88, Appendix C)

Lockwasher (Item 176, Appendix F)

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Air system drained, (TM 9-2320-364-10)

Wheel removed, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

Wrench, Combination 1-1/8 in.

(Item 79, Appendix G)

13-4. AXLES NO. 1, 2 AND 5 CENTRAL TIRE INFLATION SYSTEM (CTIS) 

 SPINDLE FITTINGS REPLACEMENT.

a. Removal.

NOTE

• Refer to Table 13-1 for proper air line numbers.

• Procedures for all spindles on Axles No. 1, 2 and 5 are the same. Spindle for Axle No. 5,

driver side is shown.

• Cap or plug all hoses, tubes, fittings and adapters as each item is removed.

• Remove cable ties as required.

• Tag and mark air lines prior to removal.

(1) Remove air line 2873 (1) from bulkhead fitting (2).
TM 9-2320-364-20-5

13-18 

13-4. AXLES NO. 1, 2 AND 5 CENTRAL TIRE INFLATION SYSTEM (CTIS) SPINDLE

 FITTINGS REPLACEMENT (CONT).

Table 13-1. CTIS Hoses and Tubes

Axle No. Left Side Hose No. Right Side Hose No.

1 2097 2097

2 2103 2099

5 2873 2109

(2) Remove tube (3) from bulkhead fitting (2)

and tee (4).

(3) Remove tube (5) from tee (4) and

adapters (6).

(4) Remove tee (4) from adapter (7).

(5) Remove adapters (6) and (7) from

spindle (8).

(6) Remove bulkhead fitting (2), nut (9) and

lockwasher (10) from bracket (11). Discard

lockwasher.

b. Installation.

NOTE

Install cable ties as required.

(1) Install bulkhead fitting (2) in bracket (11) with lockwasher (10) and nut (9). Do not tighten nut.

Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and

are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use 

in a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing,

wash immediately with soap and water.

(2) Coat threads of adapters (6) and (7) with sealing compound.

(3) Install adapters (6) and (7) in spindle (8).

(4) Position tee (4) on adapters (7). Do not tighten.

(5) Position tube (5) on tee (4) and adapter (7). Do not tighten.

(6) Position tube (3) on tee (4) and bulkhead fitting (2). Do not tighten.

(7) Tighten tee (4), tube (5) and tube (3) on adapter (7), adapter (6) and bulkhead fitting (2).

(8) Tighten nut (9) on bulkhead fitting (2).
TM 9-2320-364-20-5

 13-19

(9) Install air line 2873 (1) on bulkhead 

fitting (2).

c. Follow-On Maintenance:

• Install wheel, (TM 9-2320-364-10).

• Set CTIS controller to HIGHWAY position, (TM 9-2320-364-10).

• Start engine, (TM 9-2320-364-10).

• Build up air pressure to 125 psi (861 kPa).

• Shut OFF engine, (TM 9-2320-364-10).

• Check for air leaks, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

13-20 

Materials/Parts

Sealing Compound (Item 72, Appendix C)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Air system drained, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

13-5. AXLES NO. 3 AND 4 CENTRAL TIRE INFLATION SYSTEM (CTIS) SPINDLE

 FITTINGS REPLACEMENT.

a. Removal.

NOTE

• Procedures for all spindles on Axles No. 3 and 4 are the same. Spindle for Axle No. 4,

driver side is shown.

• Cap or plug all hoses, tubes, tees and adapters as each item is removed.

• Refer to Table 13-2 for air line number.

(1) Remove air line 2876 (1) from tee (2).
TM 9-2320-364-20-5

 13-21

Table 13-2. CTIS Hoses and Tubes

Axle No. Left Side Hose No. Right Side Hose No.

3 2869 2105

4 2876 2107

(2) Disconnect and remove tube (3) from tee (2)

and adapter (4).

(3) Remove tee (2) from adapter (5).

(4) Remove adapters (4) and (5) from

spindle (6).

b. Installation.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(1) Coat threads of adapter (4) and (5) with sealing compound.

(2) Install adapters (4) and (5) in spindle (6).

(3) Position tee (2) on adapter (5).

(4) Position tube (3) on tee (2) and adapter (4).

(5) Tighten tee (2) on adapter (5).

(6) Tighten tube (3) on tee (2) and adapter (4).

NOTE

Refer to Table 13-2 for air line number.

(7) Install air line 2876 (1) on tee (2).
TM 9-2320-364-20-5

13-22 

13-5. AXLES NO. 3 AND 4 CENTRAL TIRE INFLATION SYSTEM (CTIS) SPINDLE

 FITTINGS REPLACEMENT (CONT).

c. Follow-On Maintenance:

• Set CTIS controller to HIGHWAY position, (TM 9-2320-364-10).

• Start engine, (TM 9-2320-364-10).

• Build up air pressure to 125 psi (861 kPa).

• Shut OFF engine, (TM 9-2320-364-10).

• Check for leaks, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 13-23

Materials/Parts

Cable Ties (Item 25, Appendix C)

Tags, Identification (Item 88, Appendix C)

This task covers:

a. Air Line Locations b. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Air system drained, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

13-6. CENTRAL TIRE INFLATION SYSTEM (CTIS) AIR LINES REPLACEMENT.

a. Air Line Locations.

NOTE

• Tag and mark each end of air line before removal.

• Remove and repair air lines as described in Para 12-36.

• Remove and install cushion clamps and cable ties as required.

• Cap and plug air lines, fittings and adapters as each item is removed.
TM 9-2320-364-20-5

13-24 

13-6. CENTRAL TIRE INFLATION SYSTEM (CTIS) AIR LINES REPLACEMENT (CONT).

Table 13-3. Central Tire Inflation System - Air Line Locations

Item

No.

Air Line

No. From To

1 2096 CTIS front manifold Axle No. 1 manifold

2 2893 Axle No. 1, driver side, steering arm bracket Axle No. 1, driver side, axle housing

 bracket

3 2101 Axle No. 1, driver side, axle housing bracket Axle No. 1 manifold

4 2097 Axle No. 1, passenger side, axle housing bracket Axle No. 1 manifold

5 2893 Axle No. 1, passenger side, steering arm bracket Axle No. 1, passenger side, axle 

 housing bracket

6 2098 CTIS front manifold Axle No. 2 manifold

7 2893 Axle No. 2, driver side, steering arm bracket Axle No. 2, driver side, axle housing

 bracket

8 2103 Axle No. 2, driver side, axle housing bracket Axle No. 2 manifold

9 2099 Axle No. 2, passenger side, axle housing bracket Axle No. 2 manifold

10 2893 Axle No. 2, passenger side, steering arm bracket Axle No. 2, passenger side, axle

 housing bracket

11 2104 CTIS rear manifold Axle No. 3 manifold

12 2869 Axle No. 3, driver side Axle No. 3 manifold

13 2105 Axle No. 3, passenger side Axle No. 3 manifold

14 2106 CTIS rear manifold Axle No. 4 manifold

15 2871 Axle No. 4, driver side Axle No. 4 manifold

16 2107 Axle No. 4, passenger side Axle No. 4 manifold

17 2872 CTIS rear manifold Axle No. 5 manifold

18 2893 Axle No. 5, driver side, steering arm bracket Axle No. 5, driver side, axle housing

 bracket

19 2873 Axle No. 5, driver side, axle housing bracket Axle No. 5 manifold

20 2109 Axle No. 5, passenger side, axle housing bracket Axle No. 5 manifold

21 2893 Axle No. 5, passenger side, steering arm bracket Axle No. 5, passenger side, axle

 housing bracket

b. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 13-25

Materials/Parts

Tags, Identification (Item 88, Appendix C)

Locknut (Item 106, Appendix F)

Washer, Star (2) (Item 354, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

13-7. CENTRAL TIRE INFLATION SYSTEM (CTIS) CONTROLLER REPLACEMENT.

a. Removal.

NOTE

• Tag and mark all wire connectors prior to removal.

• If replacing knob only, go to Step (5).

(1) Remove connectors MC35 (1), MC111 (2), MC110 (3), MC105 (4) from rear of CTIS controller (5).
TM 9-2320-364-20-5

13-26 

13-7. CENTRAL TIRE INFLATION SYSTEM (CTIS) CONTROLLER 

 REPLACEMENT (CONT).

(2) Remove locknut (6) and three ground straps

(8) from CTIS mounting stud (9). Discard

locknut.

(3) Remove two nuts (10) and star washers (11)

from CTIS controller mounting studs (9).

Discard star washers.

(4) Remove CTIS controller (5) from dash

panel (12) and CTIS controller mounting

bracket (13).

(5) Remove two screws (14) and knob (15) from

CTIS controller (5).

b. Installation.

NOTE

Perform Step (1) if knob was

removed.

(1) Install knob (15) on CTIS controller (5) with

two screws (14).
TM 9-2320-364-20-5

 13-27

(2) Install CTIS controller (5) in dash panel (12)

and CTIS controller mounting bracket (13).

(3) Install two star washers (11) and nuts (10) 

on CTIS controller mounting studs (9).

(4) Install three ground wires (8) and locknut (6)

on CTIS mounting stud (9).

(5) Install connectors MC105 (4), MC35 (1),

MC111 (2) and MC110 (3) on rear of CTIS

controller (5).

c. Follow-On Maintenance:

• Connect batteries, (Para 7-87).

• Check CTIS controller operation, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

13-28 

Materials/Parts

Cable Ties (Item 26, Appendix C)

Sealing Compound (Item 72, Appendix C)

Tags, Identification (Item 88, Appendix C)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Air system drained, (TM 9-2320-364-10)

Front access cover open, (TM 9-2320-364-10)

Electronic Control Box (ECB) right side panel

removed, (Para 17-21)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Combination, 2 in.

(Item 88, Appendix G)

Wrench, Torque (0 to 60 N.

m)

(Item 98, Appendix G)

Materials/Parts - Continued

Lockwasher (4) (Item 195, Appendix F)

Lockwasher (Item 189, Appendix F)

Locknut (4) (Item 106, Appendix F)

Locknut (4) (Item 140, Appendix F)

13-8. CENTRAL TIRE INFLATION SYSTEM (CTIS) FRONT MANIFOLD

 REPLACEMENT.

a. Removal.

NOTE

• Remove cable ties as required.

• Cap and plug all hoses, fittings and adapters as each item is removed.

• Note location and position of fittings, elbows and tube prior to removal.

• Tag and mark all hoses, connectors and wires prior to removal.

(1) Remove screw (1) and lockwasher (2) from CTIS front manifold (3). Discard lockwasher.

(2) Remove air line 2074 (4) from fitting (5).

(3) Remove air line 2993 (6) from fitting (7).
TM 9-2320-364-20-5

 13-29

(4) Remove hose 2096 (8) from elbow (9).

(5) Remove hose 2098 (10) from elbow (11).

(6) Remove MC109 connector (12) from front CTIS manifold (3).

(7) Remove three screws (13), lockwashers (14) and CTIS front manifold valve cover (15) from CTIS front

manifold (3). Discard lockwashers.

(8) Remove screw (16), lockwasher (17), wire 1063 (18) and wire 1063 (19) from CTIS front manifold (3).

Discard lockwasher.
TM 9-2320-364-20-5

13-30 

13-8. CENTRAL TIRE INFLATION SYSTEM (CTIS) FRONT MANIFOLD 

 REPLACEMENT (CONT).

(9) Cut two cable ties (20) and remove vent

hose (21) from exhaust tube (22).

Support CTIS front manifold

during removal. Failure to 

comply may result in damage to

equipment.

(10) Remove four locknuts (23), screws (24) and

CTIS front manifold bracket (25) from

crossmember (26). Discard locknuts.

(11) Remove four locknuts (27), screws (28) and

CTIS manifold mount bracket (25) from

CTIS manifold (3). Discard locknuts.

(12) Remove exhaust tube (29) from fitting (30).

(13) Remove fitting (30) from CTIS front

manifold (3).

(14) Remove elbow (31), elbow (32), elbows

(33) and (34) and plugs (35) and (36) from

CTIS front manifold (3).
TM 9-2320-364-20-5

 13-31

b. Installation.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

NOTE

• Ensure fittings and elbows

are installed as noted prior to

removal.

• Install cable ties as required.

(1) Apply sealing compound on threads of

plugs (35) and (36).

(2) Install plugs (35) and (36) on CTIS front

manifold (3).

(3) Apply sealing compound on threads of

elbows (33) and (34).

(4) Install elbows (33) and (34) on CTIS front

manifold (3).

(5) Apply sealing compound on threads of

elbow (32).

(6) Install elbow (32) on CTIS manifold (3).

(7) Apply sealing compound on threads of

elbow (31).

(8) Install elbow (31) on CTIS manifold (3).

(9) Apply sealing compound on threads of

fitting (30).

(10) Install fitting (30) on CTIS front

manifold (3).

(11) Install exhaust tube (29) on fitting (30).
TM 9-2320-364-20-5

13-32 

13-8. CENTRAL TIRE INFLATION SYSTEM (CTIS) FRONT MANIFOLD 

 REPLACEMENT (CONT).

(12) Install CTIS manifold (3) on CTIS manifold

bracket (25) with four screws (28) and

locknuts (27).

(13) Install CTIS front manifold bracket (25)

and locknuts (23) on crossmember (26)

with four screws (24).

(14) Install vent hose (21) on exhaust tube (22)

with two cable ties (20).

(15) Install wire 1063 (18) and wire 1063 (19)

on CTIS front manifold (3) with

lockwasher (17) and screw (16).
TM 9-2320-364-20-5

 13-33

(16) Connect connector (12) to CTIS front

manifold (3).

(17) Install CTIS front manifold valve cover

(15) on CTIS front manifold (3) with three

lockwashers (14) and screws (13). Tighten

screws to 75 lb-in (8 N.

m).

(18) Install hose 2098 (10) on elbow (11).

(19) Install hose 2096 (8) on elbow (9).

(20) Install air line 2993 (6) on fitting (7).

(21) Install air line 2074 (4) on fitting (5).

(22) Install screw (1) and lockwasher (2) in

CTIS front manifold (3). Tighten screw

to 75 lb-in (8 N.

m).

c. Follow-On Maintenance:

• Connect batteries, (Para 7-87).

• Start engine, (TM 9-2320-364-10).

• Build up air pressure to 125 psi (861 kPa).

• Shut OFF engine, (TM 9-2320-364-10).

• Operate CTIS and check for air leaks, (TM 9-2320-364-10).

• Close front access cover, (TM 9-2320-364-10).

• Install Electronic Control Box (ECB) right side panel, (Para 17-21).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

13-34 

Materials/Parts

Cable Ties (Item 26, Appendix C)

Sealing Compound (Item 72, Appendix C)

Tags, Identification (Item 88, Appendix C)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

LHS fully extended, (TM 9-2320-364-10)

Air system drained, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

Wrench, Combination, 2 in.

(Item 88, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0 to 237 N.

m])

(Item 95, Appendix G)

13-9. CENTRAL TIRE INFLATION SYSTEM (CTIS) REAR MANIFOLD REPLACEMENT.

Materials/Parts - Continued

Locknut (4) (Item 106, Appendix F)

Locknut (4) (Item 140, Appendix F)

Lockwasher (Item 189, Appendix F)

Lockwasher (4) (Item 195, Appendix F)

a. Removal.

NOTE

• Cap and plug all air lines, elbows and adapters prior to removal.

• Note location and position of elbows, fittings and tubes prior to removal.

• Tag and mark all hoses, connectors and wires prior to removal.

(1) Remove air line 2104 (1) from elbow (2).

(2) Remove air line 2872 (3) from elbow (4).

(3) Remove air line 2106 (5) from elbow (6).

(4) Remove air line 2994 (7) from elbow (8).
TM 9-2320-364-20-5

 13-35

(5) Cut three cable ties (9) and remove air

line 2074 (10) from exhaust tube (11).

(6) Remove three screws (12) and

lockwashers (13) from rear CTIS manifold

cover (14). Discard lockwashers.

(7) Remove screw (15), lockwasher (16),

washer (17), cushion clip (18) and rear CTIS

manifold cover (14) from CTIS rear

manifold (19). Discard lockwasher.

(8) Disconnect MC64 connector (20) from CTIS

rear manifold (19).

(9) Remove screw (21), lockwasher (22) and

two wires 1067 (23) from CTIS rear

manifold (19). Discard lockwasher.

Support CTIS rear manifold

during removal. Failure to 

comply may result in damage to

equipment.

(10) Remove four locknuts (24), screws (25) and

CTIS rear manifold (19) from mounting

bracket (26). Discard locknuts.
TM 9-2320-364-20-5

13-36 

13-9. CENTRAL TIRE INFLATION SYSTEM (CTIS) REAR MANIFOLD 

 REPLACEMENT (CONT).

(11) Remove four locknuts (27), screws (28) and

CTIS manifold bracket (29) from CTIS rear

manifold (19). Discard locknuts.

(12) Remove exhaust tube (30) and fitting (31)

from CTIS rear manifold (19).

(13) Remove elbow (33), elbow (34), elbows

(32) and (35) and plugs (36) and (37) from

CTIS rear manifold (19).

b. Installation.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

NOTE

Ensure elbows, fittings and tubes

are installed as noted prior to

removal.

(1) Apply sealing compound on threads of

plugs (36) and (37).

(2) Install plugs (36) and (37) in CTIS rear

manifold (19).

(3) Apply sealing compound on threads of

elbows (32) and (35).

(4) Install elbows (32) and (35) in rear CTIS manifold (19).

(5) Apply sealing compound on threads of elbow (34).

(6) Install elbow (34) in CTIS rear manifold (19).

(7) Apply sealing compound on threads of elbow (33).

(8) Install elbow (33) in CTIS rear manifold (19).

(9) Apply sealing compound on threads of fitting (31).

(10) Install fitting (31) in CTIS rear manifold (19).

(11) Install exhaust tube (30) on fitting (31).

(12) Install rear CTIS manifold (19) on CTIS manifold bracket (29) with four screws (28) and locknuts (27).
TM 9-2320-364-20-5

 13-37

(13) Install CTIS rear manifold (19) on

mounting bracket (26) with four screws

(25) and locknuts (24). Tighten locknuts

to 35 lb-ft (47 N.

m).

(14) Install two wires 1067 (23) on CTIS rear

manifold (19) with lockwasher (22) and

screw (21).

(15) Connect connector (20) on CTIS rear

manifold (19).

(16) Install rear valve cover (14) on CTIS rear

manifold (19) with three lockwashers (13)

and screws (12).

(17) Install cushion clip (18), washer (17),

lockwasher (16) and screw (15) in CTIS

rear manifold (19).

(18) Install air line 2074 (10) with three cable

ties (9) on exhaust tube (11).
TM 9-2320-364-20-5

13-38 

13-9. CENTRAL TIRE INFLATION SYSTEM (CTIS) REAR MANIFOLD 

 REPLACEMENT (CONT).

(19) Install air line 2994 (7) on elbow (8).

(20) Install air line 2106 (5) on elbow (6).

(21) Install air line 2872 (3) on elbow (4).

(22) Install air line 2104 (1) on elbow (2).

c. Follow-On Maintenance:

• Connect batteries, (Para 7-87).

• Start engine, (TM 9-2320-364-10).

• Build up air pressure to 125 psi (861 kPa).

• Shut OFF engine, (TM 9-2320-364-10).

• Operate CTIS and check for air leaks, (TM 9-2320-364-10).

• LHS in transit position, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 13-39

Materials/Parts

Sealing Compound (Item 72, Appendix C)

Tags, Identification (Item 88, Appendix C)

This task covers:

a. Disassembly c. Assembly

b. Cleaning/Inspection d. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Front or rear manifold removed,

(Para 13-8 or 13-9)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

13-10. CENTRAL TIRE INFLATION SYSTEM (CTIS) FRONT AND REAR

 MANIFOLD REPAIR.

Materials/Parts - Continued

Kit, Fasteners and Seal (Item 36, Appendix F),

(Front manifold only)

Kit, Fasteners and Seal (Item 37, Appendix F),

(Rear manifold only)

Lockwasher (Item 187, Appendix F)

a. Disassembly.

NOTE

Tag and mark all wires and

connectors prior to removal.

(1) Loosen two screws (1) and remove

connectors (2) and gaskets (3) from inflation

valve (4) and deflation valve (5). Discard

gasket.

(2) Loosen screw (6) and remove connector (7)

and gasket (8) from quick release valve (9).

Discard gasket.

(3) Disconnect connector (10) from

transducer (11).

NOTE

Perform Step (4) for front power

manifold.

(4) Disconnect connector (12).

NOTE

Rear power manifold will have

only one wire in Step (5).

(5) Remove screw (13), lockwasher (14), wire

(15), and wire (16) from power manifold

(17). Discard screw and lockwasher.
TM 9-2320-364-20-5

13-40 

13-10. CENTRAL TIRE INFLATION SYSTEM (CTIS) FRONT AND REAR 

 MANIFOLD REPAIR (CONT).

(6) Remove transducer (11) and relief valve (18)

from power manifold (17).

NOTE

Perform Step (7) for front power

manifold.

(7) Remove pressure switch (19) from power

manifold (17).

(8) Remove two nuts (20), spring washers (21),

washers (22), inflation valve solenoid (23)

and deflation valve solenoid (24) from

power manifold (17).

(9) Remove nut (25) and quick release valve

solenoid (26) from power manifold (17).

(10) Remove spool (27) and diaphram (28) from

power manifold (17).

(11) Remove preformed packing (29) and

plunger (30) from spool (27). Discard

preformed packing.

(12) Remove and discard orifice (31) from

power manifold (17).

(13) Remove spool (32), seal ring (33) and

diaphram (34) from power manifold (17).

(14) Remove preformed packing (35) and

plunger (36) from spool (32). Discard

preformed packing.
TM 9-2320-364-20-5

 13-41

(15) Remove four screws (37), quick release

valve (9) and power manifold (17) from

porting block (38). Discard screws.

(16) Remove spring (39) and diaphram (40)

from power manifold (17).

(17) Remove preformed packings (41), (42),

(43) and (44), retainer (45), spring (46) and

ball (47) from porting block (38). Discard

preformed packings.

(18) Remove five screws (48) and mounting

plate (49) from porting block (38). Discard

screws.

NOTE

Perform Step (19) for rear

manifold only.

(19) Remove plug (50) from porting block (38).

b. Cleaning and Inspection.

(1) Clean all parts.

(2) Inspect parts and valve seats for wear, nicks,

silt buildup, cracks and stripped threads.

(3) Replace all damaged parts.
TM 9-2320-364-20-5

13-42 

13-10. CENTRAL TIRE INFLATION SYSTEM (CTIS) FRONT AND REAR

 MANIFOLD REPAIR (CONT).

c. Assembly.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, washer

immediately with soap and 

water.

NOTE

Perform Steps (1) and (2) for rear

manifold only.

(1) Apply sealing compound to threads of 

plug (50).

(2) Install plug (50) in porting block (38).

(3) Install mounting plate (49) and five screws

(48) on porting block (38).

(4) Install ball (47), spring (46), retainer (45)

and preformed packings (44), (43), (42) and

(41) in porting block (38).

(5) Position diaphram (40) spring (39), quick

release valve (9) and four screws (37), in

power manifold (17).

Lowering the manifold directly

onto the porting block without

any side movement, will ensure

the preformed packings will

remain in grooves until screws

are installed. Failure to comply

could result in a faulty manifold.

(6) While holding down quick release valve (9),

position manifold (17) above porting block

(38), and install four screws (37).
TM 9-2320-364-20-5

 13-43

(7) Install plunger (36) and preformed packing

(35) in spool (32). 

(8) Install diaphram (34), seal ring (33) and

spool (32) in power manifold (17).

(9) Install orifice (31) in power manifold (17).

(10) Install valve (30) and preformed packing

(29) in spool (27).

(11) Install diaphram (28) and spool (27) in

power manifold (17).

(12) Install quick release solenoid (26) on power

manifold (17) with nut (25).

(13) Install inflation valve solenoid (23) and

deflation valve solenoid (24) on power

manifold (17) with washers (22), washers

(21) and nuts (20).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and water.

NOTE

Perform Steps (14) and (15) for

front power manifold.

(14) Apply sealing compound on threads of

pressure switch (19).

(15) Install pressure switch (19) in power

manifold (17).

(16) Apply sealing compound on threads of

relief valve (18).

(17) Install relief valve (18) in power

manifold (17).

(18) Apply sealing compound on threads of

transducer (11).

(19) Install transducer (11) in power 

manifold (17).
TM 9-2320-364-20-5

13-44 

13-10. CENTRAL TIRE INFLATION SYSTEM (CTIS) FRONT AND REAR

 MANIFOLD REPAIR (CONT).

NOTE

Rear power manifold will have

only one wire in Step (20).

(20) Install wire (16) and wire (15) on power

manifold (17) with lockwasher (14) and

screw (13).

NOTE

Perform Step (21) for front power

manifold.

(21) Connect connector (12).

(22) Connect connector (10) to transducer (11).

(23) Install gasket (8) and connector (7) on quick

release valve (9) and tighten screw (6).

(24) Install two gaskets (3) and connectors (2)

on deflation valve (5) and inflation valve

(4) and tighten screws (1).

d. Follow-On Maintenance:

• Install front or rear manifold, (Para 13-8 or 13-9).

END OF TASK
TM 9-2320-364-20-5

 13-45

Materials/Parts

Oil, Lubricating (Item 57, Appendix C)

Sealing Compound (Item 73, Appendix C)

Fastener and Seal Kit (Item 35, Appendix F)

Locknut (2) (Item 90, Appendix F)

Valve Core (Item 342, Appendix F)

This task covers:

a. Removal b. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Wheel cover removed, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

Caps, Vise Jaw (Item 9, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gage, Air Inflation (Item 25, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

Jack, Hydraulic Hand (Item 40, Appendix G)

Repair Tool, Pneumatic Tire, Valve

(Item 56, Appendix G)

Vise, Machinist’s (Item 75, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0 to 237 N.

m])

(Item 95, Appendix G)

13-11. CENTRAL TIRE INFLATION SYSTEM (CTIS) WHEEL VALVE REPAIR.

a. Removal.

NOTE

• All wheel valves are replaced

the same way.

• Axle No. 1, right side shown.

(1) Position jack under axle (1) and raise

axle (1) until tire (2) is approximately 1 in.

off of ground.
TM 9-2320-364-20-5

13-46 

13-11. CENTRAL TIRE INFLATION SYSTEM (CTIS) WHEEL VALVE REPAIR (CONT).

(2) Remove valve stem dust cap (3) from valve

stem (4).

Ensure all personnel wear proper

eye protection. Do not stand

directly in front of valve stem

when draining air from tire. Tire

is under extreme air pressure.

Failure to comply may result in

injury to personnel.

(3) Remove valve core (5) from valve stem (4)

and allow air to drain from tire (2). Discard

valve core.

NOTE

Cap and plug hoses and fittings

after removal.

(4) Remove two hoses (6) from fittings (7).

(5) Remove two tubes (8) from wheel valve (9).

(6) Remove and discard two preformed

packings (10) from tubes (8).

(7) Remove two lug nuts (11) and mounting

bracket (12) from studs (13).

(8) Remove two locknuts (14), screws (15) and

wheel valve (9) from mounting bracket (12).

Discard locknuts.

(9) Position wheel valve (9) in soft jawed vise.

(10) Remove valve stem (4) from elbow (16).

(11) Remove two fittings (7) and elbow (16)

from wheel valve (9).

(12) Remove wheel valve (9) from soft jawed

vise.
TM 9-2320-364-20-5

 13-47

b. Disassembly.

NOTE

All wheel valves are

disassembled the same way.

(1) Remove four screws (1), poppet end cover

(2), spring (3), preformed packing (4), and

poppet (5) from wheel valve (6). Discard

four screws, spring, preformed packing, and

poppet.

(2) Remove four screws (7), pilot end cover (8),

and diaphragm (9) from wheel valve (6).

Discard four screws and diaphragm.

(3) Remove piston (10) from wheel valve (6)

and preformed packing (11) from piston

(10). Discard preformed packing.

(4) Remove and discard check valve (12) and

breather (13) from wheel valve (6).

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with 

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc). 

Failure to comply may result in injury or death to personnel.

(1) Clean all metal parts with drycleaning solvent.

(2) Dry all metal parts with compressed air.

(3) Clean rubber parts with clean, dry cloth.

(4) Inspect all metal parts and valve seats for cracks, wear, nicks, silt buildup, stripped threads and other signs

of wear.

(5) Replace all damaged parts.
TM 9-2320-364-20-5

13-48 

13-11. CENTRAL TIRE INFLATION SYSTEM (CTIS) WHEEL VALVE REPAIR (CONT).

d. Assembly.

(1) Install check valve (12) and breather (13) in

wheel valve (6).

(2) Install preformed packing (11) on piston

(10).

(3) Install piston (10) in wheel valve (6).

(4) Install new diaphragm (4) and pilot end

cover (5) on wheel valve (6) with four

screws (7).

(5) Install poppet (6), preformed packing (4),

spring (3) and poppet end cover (2) on wheel

valve (6) with four screws (1).

e. Installation.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(1) Position wheel valve (9) in soft jawed vise.

(2) Apply sealing compound on threads of 

elbow (16).

(3) Install elbow (16) in wheel valve (9).

(4) Apply sealing compound on threads of valve

stem (4).

(5) Install valve stem (4) in elbow (16).

(6) Apply sealing compound on threads of two

fittings (7).

(7) Install two fittings (7) in wheel valve (9).

(8) Remove wheel valve (9) from soft jawed

vise.
TM 9-2320-364-20-5

 13-49

(9) Install wheel valve (9) on mounting

bracket (12) with two screws (15) and

locknuts (14). Tighten screws to 18 lb-ft (24

N.

m).

(10) Install mounting bracket (12) on studs (13)

with two lug nuts (11).

(11) Apply lubricating oil to two preformed

packings (10).

(12) Install two preformed packings (10) on

tubes (8).

(13) Install two tubes (8) in wheel valve (9).

(14) Install two hoses (6) on fittings (7).

(15) Install valve core (5) in valve stem (4).

(16) Refer to data plate (17) on left side

door (18) and inflate tire to HIGHWAY

setting.
TM 9-2320-364-20-5

13-50 

13-11. CENTRAL TIRE INFLATION SYSTEM (CTIS) WHEEL VALVE REPAIR (CONT).

(17) Lower jack until tire (2) is on ground and

remove jack from under axle (1).

(18) Install valve stem dust cap (3) on valve

stem (4).

f. Follow-On Maintenance:

• Start engine, (TM 9-2320-364-10).

• Build up air pressure to 125 psi (861 kPa).

• Check CTIS operation, (TM 9-2320-364-10).

• Shut OFF engine, (TM 9-2320-364-10).

• Check for air leaks, (TM 9-2320-364-10).

• Install wheel cover, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

13-12. TIRE REPAIR.

Refer to TM 9-2610-200-14, Operator/Unit/Direct Support/General Support Maintenance Manual for care, 

maintenance, repair and inspection of pneumatic tires and inner tubes.
TM 9-2320-364-20-5

 13-51

Materials/Parts

Tags, Identification (Item 89, Appendix C)

Locknuts (Item 130, Appendix F)

This task covers:

a. Installation b. Follow-On Maintenance

INITIAL SETUP Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Drill, Electric, Portable, 1/4 in.

(Item 18, Appendix G)

Drill Set, Twist (Item 20, Appendix G)

13-13. CENTRAL TIRE INFLATION SYSTEM (CTIS) CONTROLLER PROTECTION

 KIT INSTALLATION/REPLACEMENT.

a. Installation.

NOTE

• If vehicle is equipped with Central Tire Inflation System (CTIS) Controller (10214033),

protection kit can be installed.

• If vehicle is equipped with Central Tire Inflation System (CTIS) Controller

(10214033.Rev.A), protection kit is not required.

NOTE

Tag and mark all wire connectors prior to removal.

(1) Remove connector MC35 (1) from rear of CTIS controller (2).
TM 9-2320-364-20-5

13-52 

13-13. CENTRAL TIRE INFLATION SYSTEM (CTIS) CONTROLLER 

 PROTECTION KIT INSTALLATION/REPLACEMENT (CONT).

NOTE

Use CTIS controller protection

device as template.

(2) Drill two 3/16 in. (5 mm) holes in 

bracket (3).

(3) Install CTIS controller protection device (4)

onto bracket (3) using two screws (5) and

locknuts (6).

(4) Connect CTIS controller protection device

connector (7) and MC35 connector (1).

4

3

1

7

7

4

1

5

6
TM 9-2320-364-20-5

 13-53/(13-54 blank)

(5) Connect CTIS controller protection device

connector (8) on rear of CTIS controller

(2).

b. Follow-On Maintenance:

• Connect batteries, (Para 7-87).

• Check CTIS controller operation, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

SHOWN LOOKING UPWARD

8

2

TM 9-2320-364-20-5

 14-1

CHAPTER 14

STEERING SYSTEM MAINTENANCE

Para Contents Page

14-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

14-2 Steering System Service 14-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14-3 Steering Toe-In Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4

14-4 Horn Button Replacement 14-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14-5 Steering Wheel Replacement 14-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14-6 Steering Column And Bracket Replacement 14-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14-7 Steering Lock Replacement 14-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14-8 Steering Column Shaft Replacement 14-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14-9 Gear Box Steering Shaft Repair 14-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14-10 Axle No. 5 Steering Shaft Repair 14-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14-11 Axle No. 1, 2 And 5 Tie-Rod Repair 14-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14-12 Tie-Rod And Drag Link Inspection 14-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14-13 90 Degree Gear Box Replacement 14-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14-14 Steering Hydraulic Hoses And Fittings Replacement 14-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14-15 Steering Hydraulic Reservoir Repair 14-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14-16 Steering Filter Replacement 14-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14-17 Steering Filter Adapter Head Replacement 14-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14-18 Front Steering Gear Torquing Procedure 14-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14-1. INTRODUCTION. 

This chapter contains instructions for removing, replacing, installing and adjusting components of the steering system

as authorized by the Maintenance Allocation Chart (MAC) at the Unit Maintenance level.
TM 9-2320-364-20-5

14-2 

Materials/Parts

Cloth, Cleaning (Item 31, Appendix C)

Oil, Lubricating (Item 47, Appendix C)

This task covers:

a. Drain b. Fill c. Follow-On Maintenance

INITIAL SETUP

Materials/Parts - Continued

Packing, Preformed (2) (Item 237, Appendix F)

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Rear noise panel removed, (Para 17-29)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Pan, Drain (Item 47, Appendix G)

14-2. STEERING SYSTEM SERVICE.

a. Drain.

NOTE

Perform Step (1) if truck is equipped with crane. If not, go to Step (2).

(1) Position crane boom nose toward right side

rear tire.

Prolonged contact with

lubricating oil (MIL-L-2104) 

may cause a skin rash. Skin and

clothing that come in contact 

with lubricating oil should be

thoroughly washed immediately.

Saturated clothing should be

removed immediately. Areas in

which lubricating oil is used

should be well ventilated to keep

fumes to a minimum.

NOTE

Steering system capacity is 34 qt

(32 l).

(2) Position drain pan under two drain plugs (1).

(3) Remove two plugs (1) from reservoir (2).

(4) Remove and discard two preformed

packings (3) from plugs (1).
TM 9-2320-364-20-5

 14-3

b. Fill.

(1) Coat two preformed packings (3) with

lubricating oil and install on two plugs (1).

(2) Install two plugs (1) on reservoir (2).

(3) Remove drain pan from under reservoir (2).

(4) Remove cap (4) from reservoir (2).

(5) Fill reservoir (2) with lubricating oil 

(TM 9-2320-364-10).

(6) Install cap (4) on reservoir (2).

(7) Start engine.

(8) Turn steering wheel (5) left and right 12 to

15 times.

(9) Shut OFF engine.

(10) Check reservoir (2) oil level 

(TM 9-2320-364-10).

c. Follow-On Maintenance:

• Install rear noise panel, (Para 17-29).

• Stow crane (if equipped), (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

14-4 

Materials/Parts

Locknut (2) (Item 145, Appendix F)

Pin, Cotter (Item 277, Appendix F)

This task covers:

a. Adjustment b. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tires on Axle No. 1 and No. 2 inflated to 61 psi

(420 kPa), (TM 9-2320-364-10)

Tires on Axle No 5. inflated to 70 psi (482 kPa),

(TM 9-2320-364-10)

Air pressure built to 125 psi (861 kPa),

(TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Clamp, Machinist’s (Item 10, Appendix G)

Jack, Hydraulic, 12 Ton (Item 15, Appendix G)

Jackstand (4) (Item 42, Appendix G)

Tape, Measurer (Item 66, Appendix G)

14-3. STEERING TOE-IN ADJUSTMENT.

a. Adjustment.

NOTE

• Toe in adjustment procedures must be preformed with the truck in an unloaded condition or

adjustment procedures will not be accurate.

• Before truck comes to a stop, ensure that the wheels are straight. Do not turn wheels after

truck has come to a stop. Turning steering wheel after truck stops will affect accuracy of

measurements.

• Axle No. 5 is shown. Axles No. 1 and No. 2 are adjusted in the same way.

(1) Using hydraulic jack, raise Axle No. 5 (1)

off of ground so tires (2) have one in. (25.4

mm) of clearance from floor. Place

jackstands under walking beam.

NOTE

Perform Step (2) if adjusting

toe-in on Axle No. 5. If not, go

to Step (3).

(2) Hook mud flaps (3) in the upward position.
TM 9-2320-364-20-5

 14-5

NOTE

A metal scribe, punch,

screwdriver, etc. would be a

suitable marking device.

Marking device must be able to

put visible mark on tire. Jack

stand works well as stationary

object.

(3) Attach marking device to jackstands with

clamp so that marking device is at least 16

in. (406 mm) above floor level.

NOTE

Visible mark should be made as

close to centerline of tire as

possible to attain better reading.

(4) With the aid of an assistant, spin tire (2) 

and hold jack stand in place. Continue until

visible mark is on entire diameter of tire.

Repeat for other tire.

NOTE

Ensure measurement is level and taken at an equal height on each side of tire as

shown above.

(5) Measure and record distance A (front) and B (rear) on Axle No. 5 (1).
TM 9-2320-364-20-5

14-6 

14-3. STEERING TOE-IN ADJUSTMENT (CONT).

NOTE

• Toe-in is determined by subtracting distance A from distance B. Proper toe-in 

should be 1/8 in. (1.6 mm) to ±1/16 in. (1.6 mm) toe-in (B ÷ A = toe in).

• If your toe-in reading is more than 1/8 in. (1.6 mm) to ±1/16 in. (1.6 mm), check the 

tie-rod measurement.

• Tie-rods on Axle No. 1, 2 and 5 when measured from grease fitting to grease fitting should

be within the limits shown in Table 14-1.

Table 14-1. Tie-Rod Acceptable Starting Measurements

Tie-Rod Measurement

Axle No. 1 56-5/8 in. (± 1/8 in.)

Axle No. 2 54-9/16 in. (± 1/8 in.)

Axle No. 5 51-9/16 in. (± 1/8 in.)

(6) Determine toe-in (B ÷ A = toe-in).

NOTE

If distance is correct, toe-in

adjustment is complete: go to

Step (18). If distance is not

correct, continue with Step (7).

(7) Remove cotter pin (4) and loosen castle

nut (5) even with bottom of stud on tie-rod

end (6). Discard cotter pin.

Tie-rod end may unexpectedly

pop-up when pressure is applied

with hydraulic jack. Keep hands

and face clear of tie-rod end.

Failure to comply may result in

severe injury to personnel.

(8) Using hydraulic jack, press tie-rod end (6)

loose from steering arm (7).
TM 9-2320-364-20-5

 14-7

(9) Remove castle nut (5) from tie-rod end (6).

(10) Remove tie-rod (6) from steering arm (7).

(11) Remove locknut (8) from clamp (9) on

tie-rod end (6). Discard locknut (8).

NOTE

• Lengthening Axle No. 1

and Axle No. 2 tie-rod will

decrease front-side

measurement. Shortening

Axle No. 1 and Axle No. 2

tie-rod will increase frontside measurement.

• Lengthening Axle No. 5

tie-rod will increase

front-side measurement.

Shortening Axle No. 5

tie-rod will decrease

front-side measurement.

• Adjustments should be 

made by turning both

tie-rods end in or out an

even distance.

• One tie-rod end is fine, left

hand, threaded (left side)

and one tie-rod end is 

coarse, right hand, threaded

(right side). One complete

clockwise turn on the left

side tie-rod end will 

lengthen the tie-rod 1/16 in.

while one complete

clockwise turn on the right

side tie-rod end will shorten

total tie-rod 3/32 in.

(12) Turn tie-rod end (6) to lengthen or shorten

tie-rod.

(13) Install tie-rod end (6) on steering arm (7).

(14) Tighten castle nut (5) enough to prevent

tie-rod (6) from moving.

(15) Measure and determine toe-in. Repeat Steps (5) through (6).

(16) If toe-in needs adjustment, repeat Steps (7) through (15) until correct measurement is obtained.
TM 9-2320-364-20-5

14-8 

14-3. STEERING TOE-IN ADJUSTMENT (CONT).

NOTE

• For Axle No. 1 and 5 perform

Step (17).

• For Axle No. 2 perform Step

(18).

(17) Install locknut (8) on clamp (9) and tie-rod

end (6). Tighten locknut (8) on clamp (9) to

80 to 90 lb-ft (108 to 122 N.

m).

(18) Install locknut (8) and clamp (9) on tie-rod

end (6). Tighten locknut (8) on clamp (9) to

50 to 60 lb-ft (68 to 81 N.

m).

(19) Install castle nut (5) on tie-rod end (6).

Tighten castle nut (5) to 150 to 200 lb-ft

(203 to 207 N.

m).

NOTE

It may be necessary to further

tighten nut to line up slots for

cotter pin installation.

(20) Install cotter pin (4) in castle nut (5) and

tie-rod end (6).

(21) Using hydraulic jack, raise Axle No. 5 (1),

remove jackstands and lower axle.

b. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 14-9

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected (Para 7-87)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

14-4. HORN BUTTON REPLACEMENT.

a. Removal.

NOTE

Horn button will come out as an assembly.

(1) Remove horn button (1) from steering wheel (2).

(2) Disconnect wire 1016 (3) from horn button (1).

b. Installation.

(1) Connect wire 1016 (3) on horn button (1).

(2) Install horn button (1) on steering wheel (2).

c. Follow-On Maintenance:

• Connect batteries, (Para 7-87).

• Check horn operation, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

DOOR

SHOWN

REMOVED

FOR CLARITY
TM 9-2320-364-20-5

14-10 

This task covers:

a. Removal b. Installation c. Follow-on Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Horn button removed, (Para 14-4)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Puller Kit, Universal (Item 51, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0 to 237 N.

m])

(Item 95, Appendix G)

14-5. STEERING WHEEL REPLACEMENT.

a. Removal.

NOTE

• If steering column is to be removed, position steering wheel so steering column universal

joint screws can be reached.

• Note location of steering wheel on shaft prior to removal.

(1) Remove nut (1) from shaft (2).

(2) Attach puller to steering wheel (3).

(3) Using puller remove steering wheel (3) from shaft (2).

(4) Remove puller from steering wheel (3).

(5) Remove horn cancel ring (4) from column (5) or steering wheel (3).

NOTE

Perform Step (6) if removing steering column.

(6) Install nut (1) on shaft (2).

3

2

1

4

5

DOOR

SHOWN

REMOVED

FOR CLARITY
TM 9-2320-364-20-5

 14-11

b. Installation.

(1) Install horn cancel ring (4) on steering wheel

(3).

NOTE

Hold steering shaft up when

installing steering wheel.

(2) If installed, remove nut (1) from shaft (2).

(3) Install steering wheel (3) on steering

shaft (2).

(4) Install nut (1) on shaft (2). Tighten nut to 

65 lb-ft (81 N.

m).

c. Follow-On Maintenance:

• Install horn button, (Para 14-4).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

3

2

1

4

5
TM 9-2320-364-20-5

14-12 

Materials/Parts

Cable Ties (Item 25, Appendix C)

Corrosion Preventive Compound (Item 35, Appendix C)

Locknut (2) (Item 96, Appendix F)

Locknut (2) (Item 140, Appendix F)

Locknut (2) (Item 143, Appendix F)

Screw (Item 314, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Steering wheel removed, (Para 14-5)

Instrument panel removed, (Para 7-13)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0 to 237 N.

m])

(Item 95, Appendix G)

14-6. STEERING COLUMN AND BRACKET REPLACEMENT.

a. Removal.

NOTE

• Note location of wiring harness before disconnecting wire connectors.

• Remove cable ties as required.

(1) Disconnect connectors MC7 (1), MC91 (2) and MC92 (3).

(2) Remove turn signal wiring harness (4) from under dash (5).
TM 9-2320-364-20-5

 14-13

(3) Remove screw (6) and wire 1435 (7)

from bottom of dash (5). Discard screw.

(4) Remove two locknuts (8), screws (9),

brackets (10) and steering column (11) from

brackets (12) and (13). Discard locknuts.

(5) Remove two pads (14) from two 

brackets (10).

(6) Remove locknut (15), screw (16) and

steering column (11) from U-joint (17).

Discard locknut.

(7) Remove locknut (18), screw (19), U-joint

(17) and key (20) from shaft (21). Discard

locknut.
TM 9-2320-364-20-5

14-14 

14-6. STEERING COLUMN AND BRACKET REPLACEMENT (CONT).

NOTE

Perform Steps (8) through (11) if removing brackets.

(8) Loosen jam nut (22) on hand brake handle (23).

(9) Remove hand brake handle (23) from hand brake valve (24).

(10) Remove three screws (25) and hand brake valve (24) from bracket (13).

(11) Remove two screws (26), locknuts (27), and two brackets (12) and (13) from bracket support (28).

Discard locknuts.

b. Installation.

NOTE

• Perform Steps (1) through (4) if brackets were removed.

• Install cable ties as required.

(1) Install two screws (26), locknuts (27), brackets (12) and (13) on bracket support (28).

(2) Install hand brake valve (24) with three screws (25) on bracket (13).

(3) Install hand brake handle (23) in hand brake valve (24) until threads of hand brake handle bottom out in

hand brake valve.

(4) Tighten jam nut (22) on trailer hand brake handle (23) to 13 lb-ft (17 N.

m).
TM 9-2320-364-20-5

 14-15

(5) Install U-joint (17) on shaft (21) with

screw (19), locknut (18) and key (20).

(6) Install steering column (11) on U-joint (17)

with screw (16) and locknut (15).

(7) Position two pads (14) on brackets (10) and

install steering column (11) on brackets (12)

and (13) with two screws (9) and

locknuts (8). Tighten locknuts to 85 to 105

lb-ft (115 to 142 N.

m).

(8) Install wire 1435 (7) on bottom of dash (5)

with screw (6).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(9) Apply corrosion preventive compound to

screw (6).
TM 9-2320-364-20-5

14-16 

14-6. STEERING COLUMN AND BRACKET REPLACEMENT (CONT).

(10) Position turn signal wire harness (4) under

and behind dash (5).

(11) Connect connectors MC7 (1), MC91 (2)

and MC92 (3).

c. Follow-On Maintenance:

• Install instrument panel, (Para 7-13).

• Install steering wheel, (Para 14-5).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 14-17

Materials/Parts

Lockwasher (4) (Item 168, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Steering column removed, (Para 14-6)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

14-7. STEERING LOCK REPLACEMENT.

a. Removal.

NOTE

Washer may or may not be

present in Step (1).

(1) Remove washer (1), if present, and lock

bracket (2) from gear box (3).

(2) Remove two screws (4), lockwashers (5) and

bracket (6) from gear box (3). Discard

lockwashers.

(3) Remove two screws (7), lockwashers (8) and

bracket (9) from gear box (3). Discard

lockwashers.

b. Installation.

(1) Install bracket (9) on gearbox (3) with two

lockwashers (8) and screws (7).

(2) Install bracket (6) on gearbox (3) with two

lockwashers (5) and screws (4).

NOTE

• Lock bracket should be

pointing straight down.

• If lock bracket is making

contact with steering gear

bracket install washer.

• Washer may or may not be

present in Step (3).

(3) Install lock bracket (2) and washer (1), if

necessary, on gear box (3).
TM 9-2320-364-20-5

14-18 

14-7. STEERING LOCK REPLACEMENT (CONT).

c. Follow-On Maintenance:

• Install steering column, (Para 14-6).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 14-19

Materials/Parts

Locknut (Item 133, Appendix F)

Locknut (Item 143, Appendix F)

Lockwasher (3) (Item 168, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Front access cover open, (TM 9-2320-364-10)

90 degree gear box removed, (Para 14-13)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

14-8. STEERING COLUMN SHAFT REPLACEMENT.

a. Removal.

(1) Remove locknut (1) and screw (2) from U-joint (3). Discard locknut.
TM 9-2320-364-20-5

14-20 

14-8. STEERING COLUMN SHAFT REPLACEMENT (CONT).

(2) Remove steering shaft assembly (4) from

bearing (5).

(3) With the aid of an assistant, remove three

nuts (6), screws (7), retaining plate (8),

bearing (5) and retaining plate (9) from

cab (10). Discard lockwashers.

NOTE

Note location and position of yoke on steering gear prior to removal.

(4) Remove locknut (11), screw (12) and steering shaft (13) from steering gear (14). Discard locknut.

b. Installation.

NOTE

Ensure yoke on steering gear is installed as noted prior to removal.

(1) Install steering shaft (13) on steering gear (14) with screw (12) and locknut (11).
TM 9-2320-364-20-5

 14-21

(2) With the aid of an assistant, install retaining

plate (9), bearing (5) and retaining plate (8)

in cab (10) with three screws (7) and nuts

(6).

(3) Install steering shaft assembly (4) in

bearing (5).

(4) Install screw (2) and locknut (1) on

U-joint (3).

c. Follow-On Maintenance:

• Install 90 degree gearbox, (Para 14-13).

• Close front access cover, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

14-22 

Materials/Parts

Cable Ties (2) (Item 25, Appendix C)

Cross and Bearing (Item 28, Appendix F)

Fitting, Lubrication (Item 42, Appendix F)

Key (Item 85, Appendix F)

Locknut (Item 133, Appendix F)

Locknut (Item 143, Appendix F)

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Bar, Crow (Item 4, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Airblow (Item 31, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0 to 24 N.

m])

(Item 95, Appendix G)

14-9. GEAR BOX STEERING SHAFT REPAIR.

a. Removal.

NOTE

• Note location and position of steering shaft yokes on intermediate steering box and gear

reduction box prior to removal.

• Do not move truck during replacement of steering shaft. If wheels are moved, notify 

Direct Support to perform steering timing procedure.

(1) Remove locknut (1), screw (2) and steering shaft (3) from intermediate steering gear assembly (4). Discard

locknut.
TM 9-2320-364-20-5

 14-23

(2) Remove locknut (5), screw (6), steering shaft

(3) and key (7) from reduction gear box (8).

Discard locknut and key.

b. Disassembly.

(1) Position steering shaft (1) on clean work surface.

(2) Remove lube fitting (2) from steering shaft (1).

(3) Remove two tie straps (3) from dust boot (4) and position dust boot (4) on yoke end (5).

(4) Remove screw (6) from dust cap (7).

(5) Remove yoke end (5), dust boot (4), dust cap (7) and ring clamp (8) from steering shaft (1).
TM 9-2320-364-20-5

14-24 

14-9. GEAR BOX STEERING SHAFT REPAIR (CONT).

NOTE

• Rod end clevis and yoke end

cross and bearing assemblies

are removed the same way.

• Rod end clevis shown.

(6) Remove lube fitting (9) from cross and

bearing assembly (10).

Use care when removing

retaining rings. Retaining rings

are under spring tension and can

act as projectiles when released

and could cause severe eye injury.

(7) Remove four retaining rings (11) from cross

and bearing assembly (10).

Use caution when removing

bearing assemblies. Needles in

bearing assemblies may become

lost or damaged.

(8) Remove four bearing assemblies (12) from

steering shaft (1) and rod end clevis (13).

(9) Remove rod end clevis (13) and cross and

bearing assembly (8) from steering shaft (1).

(10) Repeat Steps (6) through (9) for yoke end

cross and bearing assembly removal.
TM 9-2320-364-20-5

 14-25

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

(1) Clean all metal parts with drycleaning solvent.

Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).

Failure to comply may result in injury or death to personnel.

(2) Dry all parts with compressed air.

(3) Inspect steering shaft for cracks or dents.

(4) Inspect universal joint for pitting and gouges.

(5) Inspect bearing caps for cracks or missing needle bearings.

(6) Inspect splines and dust cap for cracks.

(7) Replace all damaged parts.
TM 9-2320-364-20-5

14-26 

14-9. GEAR BOX STEERING SHAFT REPAIR (CONT).

d. Assembly.

NOTE

• Rod end clevis and yoke end cross and bearing assemblies are installed the same way.

• Rod end clevis shown.

(1) Position cross and bearing assembly (10) and

rod end clevis (13) in steering shaft (1).

Use caution when installing

bearing assemblies. Needles in

bearing assemblies may become

lost or damaged.

(2) Install four bearing assemblies (12) in

steering shaft (1) and rod end clevis (13).

Use care when installing retaining rings. Retaining rings are under spring tension and can

act as projectiles when released and could cause severe eye injury.

(3) Install four retaining rings (11) on cross and bearing assembly (10).

(4) Install lube fitting (9) on cross and bearing assembly (10).

(5) Repeat Steps (1) through (4) for yoke end cross and bearing assembly installation.
TM 9-2320-364-20-5

 14-27

(6) Position ring clamp (8), dust cap (7), dust boot (4) and yoke end (5) on steering shaft (1).

(7) Install screw (6) in dust cap (7).

(8) Install dust boot (4) on yoke end (5) and steering shaft (1), using two tie straps (3).

(9) Install lube fitting (2) on steering shaft (1).

e. Installation.

(1) Install key (7) on reduction gear box (8).

NOTE

• Align key on gear reduction

box with slot in yoke.

• Ensure steering shaft yokes

are installed as noted prior 

to removal.

(2) Install steering shaft (3) on reduction gear

box (8).

(3) Install screw (6) and locknut (5) on steering

shaft (3).
TM 9-2320-364-20-5

14-28 

14-9. GEAR BOX STEERING SHAFT REPAIR (CONT).

(4) Install steering shaft (3) on intermediate

steering gear assembly (4).

(5) Install screw (2) and locknut (1) on steering

shaft (3).

f. Follow-On Maintenance:

• Lubricate steering shaft, (Para 2-9).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 14-29

Materials/Parts

Cable Ties (2) (Item 25, Appendix C)

Cross and Bearing (Item 28, Appendix F)

Fitting, Lubrication (Item 42, Appendix F)

Locknut (Item 133, Appendix F)

Locknut (Item 143, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Bar, Crow (Item 4, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Airblow (Item 31, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0 to 237 N.

m])

(Item 95, Appendix G)

14-10. AXLE NO. 5 STEERING SHAFT REPAIR.

a. Removal.

NOTE

• Note location and position of steering shaft yoke on steering gear prior to removal.

• Do not move truck during replacement. If wheels are moved, notify Direct Support to

perform steering timing procedure.

(1) Remove locknut (1), screw (2) and steering shaft (3) from splined end of steering gear (4). 

Discard locknut.
TM 9-2320-364-20-5

14-30 

14-10. AXLE NO. 5 STEERING SHAFT REPAIR (CONT).

(2) Remove locknut (5), screw (6), steering

shaft (3) from steering shaft (7). Discard

locknut.

b. Disassembly.

(1) Position steering shaft (1) on clean work

surface.

(2) Remove lube fitting (2) from steering shaft (1).

(3) Remove two tie straps (3) from dust boot (4)

and position dust boot (4) on yoke end (5).

(4) Remove screw (6) from dust cap (7).

(5) Remove yoke end (5), dust boot (4), dust cap

(7) and ring clamp (8) from steering shaft (1).
TM 9-2320-364-20-5

 14-31

NOTE

• Rod end clevis and yoke end

cross and bearing assemblies

are removed the same way.

• Rod end clevis shown.

(6) Remove lube fitting (9) from cross and

bearing assembly (10).

Use care when removing

retaining rings. Retaining rings

are under spring tension and can

act as projectiles when released

and could cause severe eye injury.

(7) Remove four retaining rings (11) from cross

and bearing assembly (10).

Use caution when removing

bearing assemblies. Needles in

bearing assemblies may become

lost or damaged.

(8) Remove four bearing assemblies (12) from

steering shaft (1) and rod end clevis (13).

(9) Remove rod end clevis (13) and cross and

bearing assembly (10) from steering shaft

(1).

(10) Repeat Steps (6) through (9) for yoke end

cross and bearing assembly removal.
TM 9-2320-364-20-5

14-32 

14-10. AXLE NO. 5 STEERING SHAFT REPAIR (CONT).

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

(1) Clean all metal parts with drycleaning solvent.

Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).

Failure to comply may result in injury or death to personnel.

(2) Dry all parts with compressed air.

(3) Inspect steering shaft for cracks or dents.

(4) Inspect universal joint for pitting and gouges.

(5) Inspect bearing caps for cracks or missing needle bearings.

(6) Inspect splines and dust cap for cracks.

(7) Replace all damaged parts.
TM 9-2320-364-20-5

 14-33

d. Assembly

NOTE

• Rod end clevis and yoke end cross and bearing assemblies are installed the same way.

• Rod end clevis shown.

(1) Position cross and bearing assembly (10) and

rod end clevis (13) in steering shaft (1).

Use caution when installing

bearing assemblies. Needles in

bearing assemblies may become

lost or damaged.

(2) Install four bearing assemblies (12) in

steering shaft (1) and rod end clevis (13).

Use care when installing retaining rings. Retaining rings are under spring tension and can

act as projectiles when released and could cause severe eye injury.

(3) Install four retaining rings (11) on cross and bearing assembly (10).

(4) Install lube fitting (9) on cross and bearing assembly (10).

(5) Repeat Steps (1) through (4) for yoke end cross and bearing assembly installation.
TM 9-2320-364-20-5

14-34 

14-10. AXLE NO. 5 STEERING SHAFT REPAIR (CONT).

(6) Position ring clamp (8), dust cap (7), dust boot (4) and yoke end (5) on steering shaft (1).

(7) Install screw (6) in dust cap (7).

(8) Install dust boot (4) on yoke end (5) and steering shaft (1), using two tie straps (3).

(9) Install lube fitting (2) on steering shaft (1).

e. Installation.

(1) Collapse steering shaft (3) slightly and

install yoke (8) on steering shaft (7).

(2) Install screw (6) and nut (5) in yoke (8).

Tighten to 35 lb-ft (47 N.

m).
TM 9-2320-364-20-5

 14-35

NOTE

Ensure steering shaft yokes are

installed as noted prior 

to removal.

(3) Install yoke (9) on steering gear shaft (4).

(4) Install screw (2) and locknut (1) in yoke (9)

and steering gear (4). Tighten to 35 lb-ft 

(47 N.

m).

f. Follow-On Maintenance:

• Lubricate steering shaft, (Para 2-9).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

14-36 

Materials/Parts

Solvent, Drycleaning (Item 87, Appendix C)

Locknut (Item 127, Appendix F)

Pin, Cotter (2) (Item 277, Appendix F)

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Wheel/tire removed, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

Jack Kit, Hydraulic, Hand (Item 41, Appendix G)

Tape Measure (Item 66, Appendix G)

Wrench, Combination 1-5/16 in.

(Item 81, Appendix G)

Wrench, Torque (0 to 175 [0 to 237 N.

m])

(Item 95, Appendix G)

14-11. AXLE NO. 1, 2 AND 5 TIE-ROD REPAIR.

a. Removal.

NOTE

• Note location of tie-rod ends prior to removal.

• All tie rods are removed the same. Axle No. 2 shown.

(1) Remove cotter pin (1) and loosen castle nut (2) until it is flush with bottom of stud on tie-rod end (3).

Discard cotter pins.
TM 9-2320-364-20-5

 14-37

Tie-rod end may unexpectedly

pop-up when pressure is applied

with hydraulic jack. Keep hands

and face clear of tie-rod end.

Failure to comply may result in

severe injury to personnel.

(2) Position hydraulic hand jack under tie-rod

end (3).

(3) Using hydraulic hand jack, press tie-rod

end (3) from steering arm (4).

(4) Remove hydraulic jack from under tie-rod

end (3).

(5) Remove castle nut (2) from tie-rod end (3).

(6) Repeat Steps (1) through (5) to remove

remaining tie-rod end.

b. Disassembly.

NOTE

• Note location and position of

tie-rod ends prior to removal.

• Both tie-rod ends are

removed the same way.

(1) Remove locknut (1) and screw (2) from

clamp. Discard locknut.

(2) Remove tie-rod end (3) from tie-rod (4).

NOTE

Do not perform Steps (3) and (4)

if tie-rod end is lube for life.

These are permanently lubricated,

have no lube fitting, and dust

cover is part of tie-rod end.

(3) Remove dust cover (5) from tie-rod end (3).

NOTE

Perform Step (4) if grease fitting

is damaged.

(4) Remove grease fitting (6) from tie-rod end (3).

(5) Repeat Steps (1) through (4) for remaining tie-rod end (3).
TM 9-2320-364-20-5

14-38 

14-11. AXLE NO. 1, 2 AND 5 TIE-ROD REPAIR (CONT).

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc).

Failure to comply may result in injury or death to personnel.

(1) Clean all metal parts with drycleaning solvent.

(2) Dry all metal parts with compressed air.

(3) Clean rubber parts with clean, dry cloth.

(4) Inspect all metal parts for cracks, stripped threads and other signs of wear.

(5) Replace all damaged parts.
TM 9-2320-364-20-5

 14-39

d. Assembly.

NOTE

• Both tie-rod ends are

installed the same way.

• Ensure tie-rod ends are

installed as noted prior to

removal.

• Perform Step (1) if grease

fitting was removed.

• Do not perform Steps (1) and

(2) if tie-rod end is lube for

life.

(1) Install grease fitting (6) on tie-rod end (3).

(2) Install dust cover (5) on tie-rod end (3).

NOTE

Ensure that tie-rod and tie-rod

ends are pointed in same

direction.

(3) Install tie-rod end (3) on tie-rod (4).

(4) Position screw (2) and locknut (1) in clamp.

(5) Repeat Steps (1) through (4) for remaining

tie-rod end (3).

NOTE

If tie-rod rod ends are lube for

life, measure at center of tie-rod

ends.

(6) Measure distance between two grease

fittings (6) on tie-rod ends (3).

(7) Turn tie-rod ends (3) in or out evenly until

measurement between grease fittings (6) are

in compliance with Table 14-2.

Table 14-2. Tie-Rod Measurements

Tie-Rod Measurement

Axle No. 1 56-5/8 in.

Axle No. 2 54-9/16 in.

Axle No. 5 51-9/16 in.
TM 9-2320-364-20-5

14-40 

14-11. AXLE NO. 1, 2 AND 5 TIE-ROD REPAIR (CONT).

e. Installation.

• Tie-rod ends must be threaded into tie-rod so threads are beyond opening under clamp or

damage to equipment will result.

• Do not turn tire to get drag link to fit. This will cause improper toe-in and damage to

equipment may result.

NOTE

• One complete revolution of tie-rod end lengthens or shortens tie-rod 0.3125 in. (8 mm).

• Ensure tie-rod ends are installed as noted prior to removal.

• For Axle No. 1 and 5 Perform Step (1).

• For Axle No. 2 Perform Step (2).

(1) Tighten locknut (6) on screw (7) to 80 to 90

lb-ft (108 to 122 N.

m).

(2) Tighten locknut (6) on screw (7) to 50 to 60

lb-ft (68 to 81 N.

m).

(3) Install tie-rod (2) on two steering arms (3).

(4) Install castle nut (4) on each tie-rod end (1).

Tighten castle nuts to 150 to 200 lb-ft (203

to 271 N.

m).

NOTE

Castle nut may need to be 

rotated slightly to install cotter

pin.

(5) Install cotter pins (5) in castle nuts (4).

f. Follow-On Maintenance:

• Install wheel/tires, (TM 9-2320-364-10).

• Adjust toe-in, (Para 14-3).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 14-41

This task covers:

a. Inspection b. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Gloves, Heavy Duty

(Item 29, Appendix G)

14-12. TIE-ROD AND DRAG LINK INSPECTION.

a. Inspection.

NOTE

Tie-rod and drag link end wear is determined by the amount of axial movement in the end.

The arrow in the illustration shows the direction of axial movement in the end. Side to side,

twisting or lateral movement is NOT an indication of end wear.

(1) Ensure wheels are straight ahead with no tension or binding on steering linkage and components.

Use hand force only in performing this inspection. Using mechanical and other leverage

such as pry bars may damage the equipment.

(2) Using hand force only, check for wear of tie-rod ends or drag link ends (1) by pulling and pushing in a

straight in and out motion only.

1
TM 9-2320-364-20-5

14-42 

14-12. TIE-ROD AND DRAG LINK INSPECTION (CONT).

(3) Measure results. If:

(a) If movement is 1/8 inch (3.2 mm) or less no further action is required.

(b) If movement is between 1/16th inch (1.6 mm) and 1/8th inch (3.2 mm) plan to replace the end at the

next scheduled service interval.

(c) If tie-rod end movement is 1/8th inch (3.2 mm) or more replace end immediately (Para 14-11). If

drag link movement is greater than 1/8th inch (3.2 mm) notify Direct Support.

b. Follow-On Maintenance

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 14-43

Materials/Parts

Locknut (Item 140, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Steering lock removed, (Para 14-7)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0 to 237 N.

m])

(Item 95, Appendix G)

14-13. 90 DEGREE GEAR BOX REPLACEMENT.

a. Removal.

(1) Remove locknut (1) and screw (2) from

yoke (3). Discard locknut.

Support gear box to keep gear box

from falling or damage to

equipment may result.

(2) Remove four screws (4) and gear box (5)

from bracket (6).

(3) Remove gear box (5) from yoke (3).
TM 9-2320-364-20-5

14-44 

14-13. 90 DEGREE GEAR BOX REPLACEMENT (CONT).

b. Installation.

Place support under gear box to

keep gear box from falling or

damage to equipment may 

result.

(1) Position gear box (5) on yoke (3).

(2) Install gear box (5) on bracket (6) with four

screws (4).

(3) Install screw (2) and locknut (1) on yoke (3).

Tighten screw 19 to 30 lb-ft (25 to 41 N.

m).

c. Follow-On Maintenance:

• Install steering lock, (Para 14-7).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 14-45

Materials/Parts

Cable Ties (Item 26, Appendix C)

Tags, Identification (Item 88, Appendix C)

This task covers:

a. Hose Locations b. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Steering reservoir drained, (Para 14-2)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

14-14. STEERING HYDRAULIC HOSES AND FITTINGS REPLACEMENT.

a. Hose Locations.

Equipment may be damaged by foreign matter if hoses, tubes and connectors are not plugged

and capped when removed.

NOTE

• This procedure is for reference only to show location of hoses used on the truck. It will

never be necessary to remove all hoses at one time. Individual tasks will indicate the area

where hoses are removed and installed.

• As items are removed, cap and plug all hoses, tubes and connectors.

• Tag and mark all hoses, pipes and tubes before removal.

• Remove and replace cable ties as required.

• Remove clamps and support brackets as required.
TM 9-2320-364-20-5

14-46 

14-14. STEERING HYDRAULIC HOSES AND FITTINGS REPLACEMENT (CONT).

Table 14-3. Steering Hydraulic Hose Locations

Hose No. From To

2883 Steering Filter, Front (1) 3/4-in. Hydraulic Tube (2)

2726 Steering Valve, Rear, Lower (3) 3/4-in. Hydraulic Tube (2)

2301 Steering Valve, Left Upper, Rear (3) Front Steering Gear, Front (4)

2274 Steering Valve, Left, Lower, Rear (3) 1/2-in. Hydraulic Tube, Front (4)

2503 Main Hydraulic Pump Manifold, Front (6) Main Steering Pump, Left Side Center (7)

2907 Main Hydraulic Pump Manifold, Rear, (6) Aux Steering Manifold, Rear, Lower, Left (8)

2393 Steering Valve, Left, Upper (3) Main Steering Pump Manifold, Left, Center (6)

2496 Steering Valve, Left, Lower Left (3) Aux Steering Manifold, Lower, Right (8)

2506 Aux Steering Pump, Bottom, Left (9) Aux Steering Pump, Upper (8)

2701 Steering Reservoir, Front, Center, 

 Lower Tee (10)

 Main Steering Pump, Right Rear (7)

2278 Steering Reservoir, Front, Left (10) Main Steering Pump, Right Rear (7)

2302 Steering Reservoir, Front, Right (10) Aux Steering Pump, Right, Front (7)

2553 Steering Reservoir, Right (10) Steering Filter, Rear (1)

2276 3/4-in. Hydraulic Tube, Rear (2) Rear Steering Gear, Rear (11)

2275 1/2-in. Hydraulic Tube, Rear (5) Rear Steering Gear, Top (11)

2877 Front Steering Gear, Bottom (4) Slave Steering Gear, Front (12)

2878 Front Steering Gear, Top, Front (4) Slave Steering Gear, Top (12)

2928 Front Steering Gear, Top, Rear (4) Steering Valve, Rear, Top (3)

2286 Aux Steering Pump, Upper Rear, Center (8) Reservoir, Front, Center, Tee (10)

b. Follow-On Maintenance:

• Fill steering reservoir, (LO 9-2320-364-12).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 14-47

Materials/Parts

Oil, Lubricating (Item 47, Appendix C)

Solvent, Drycleaning (Item 87, Appendix C)

Gasket (Item 50, Appendix F)

Gasket (Item 70, Appendix F)

Locknut (4) (Item 96, Appendix F)

Locknut (21) (Item 106, Appendix F)

Packing, Preformed (3) (Item 226, Appendix F)

Packing, Preformed (Item 231, Appendix F)

Packing, Preformed (Item 232, Appendix F)

Packing, Preformed (Item 234, Appendix F)

Packing, Preformed (2) (Item 251, Appendix F)

Packing, Preformed (Item 255, Appendix F)

Packing, Preformed (Item 259, Appendix F)

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Left side noise panel removed, (Para 17-28)

Steering reservoir drained, (Para 14-2)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical and Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

Pan, Drain (Item 46, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Combination, 1-1/8 in.

(Item 79, Appendix G)

Wrench, Combination, 1-3/8 in.

(Item 82, Appendix G)

Wrench, Combination, 1-7/8 in.

(Item 87, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0 to 237 N.

m])

(Item 95, Appendix G)

Wrench, Torque, (0 to 60 N.

m)

(Item 98, Appendix G)

14-15. STEERING HYDRAULIC RESERVOIR REPAIR.
TM 9-2320-364-20-5

14-48 

14-15. STEERING HYDRAULIC RESERVOIR REPAIR (CONT).

a. Removal.

NOTE

• Tag and mark all hoses prior to removal.

• Cap and plug hoses and fittings as removed.

(1) Remove hose 2553 (1) from elbow (2). Remove and discard preformed packing (3).

(2) Remove hose 2701 (4) and preformed packing (5) from tee (6). Discard preformed packing.

(3) Remove hose 2286 (7) and preformed packing (8) from tee (6). Discard preformed packing.

(4) Remove hose 2302 (9) and preformed packing (10) from elbow (11). Discard preformed packing.

(5) Remove hose 2278 (12) and preformed packing (13) from elbow (14). Discard preformed packing.
TM 9-2320-364-20-5

 14-49

(6) Remove two locknuts (15) and screws (16)

from bracket (17). Discard locknuts.

(7) Remove two locknuts (18), screws (19) and

reservoir (20) from bracket (17). Discard

locknuts.

(8) Remove three locknuts (21), screws (22) and

bracket (23) from reservoir (20). Discard

locknuts.
TM 9-2320-364-20-5

14-50 

14-15. STEERING HYDRAULIC RESERVOIR REPAIR (CONT).

b. Disassembly.

NOTE

Note position of elbows and tee

prior to removal.

(1) Remove elbow (1) and preformed

packing (2) from reservoir (3). Discard

preformed packing.

(2) Remove elbow (4) and preformed

packing (5) from reservoir (3). Discard

preformed packing.

(3) Remove elbow (6) and preformed

packing (7) from reservoir (3). Discard

preformed packing.

(4) Remove tee (8) and preformed packing (9)

from reservoir (3). Discard preformed

packing.

(5) Remove cap (10) from strainer (11).

(6) Remove chain (12) from cap (10).

(7) Remove and discard preformed

packing (13) from cap (10).

(8) Remove six screws (14), lockwashers (15)

and steel basket (11) from reservoir (3).

Discard lockwashers.

(9) Remove and discard gasket (16) from steel

basket (11).

(10) Remove 18 locknuts (17), screws (18),

bracket (19), cover (20) and gasket (21)

from reservoir (3). Discard locknuts and

gasket.
TM 9-2320-364-20-5

 14-51

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc).

Failure to comply may result in injury or death to personnel.

(1) Clean all metal parts with drycleaning solvent and dry with compressed air.

(2) Inspect metal parts for breaks, cracks, and sharp edges.

(3) Replace all damaged parts.
TM 9-2320-364-20-5

14-52 

14-15. STEERING HYDRAULIC RESERVOIR REPAIR (CONT).

d. Assembly.

(1) Position gasket (21), cover (20) and bracket (19) on reservoir (3) with 18 screws (18) and locknuts (17).

(2) Tighten screws (18) in sequence shown and in following Steps:

(a) Step 1: 40 lb-in (5 N.

m).

(b) Step 2: 50 to 55 lb-in (6 N.

m).

(3) Position gasket (16) and strainer (11) on reservoir (3) with six lockwashers (15) and screws (14).

(4) Run all screws (14) down evenly until screw heads contact strainer (11).

(5) Tighten each screw (14) one full turn.

(6) Install preformed packing (13) on cap (10).

(7) Install chain (12) on cap (10).

(8) Install cap (10) on steel basket (11).
TM 9-2320-364-20-5

 14-53

NOTE

Install fittings as noted prior to

removal.

(9) Apply lubricating oil on preformed

packing (9).

(10) Install preformed packing (9) on tee (8).

(11) Install tee (8) in reservoir (3).

(12) Apply lubricating oil to preformed

packing (7).

(13) Install preformed packing (7) on elbow (6).

(14) Install elbow (6) in reservoir (3).

(15) Apply lubricating oil to preformed

packing (5).

(16) Install preformed packing (5) on elbow (4).

(17) Install elbow (4) in reservoir (3).

(18) Apply lubricating oil to preformed

packing (2).

(19) Install preformed packing (2) on elbow (1).

(20) Install elbow (1) in reservoir (3).

e. Installation.

(1) Install bracket (23) on reservoir (20) with

three screws (22) and locknuts (21). Tighten

to 75 lb-in (8 N.

m).
TM 9-2320-364-20-5

14-54 

14-15. STEERING HYDRAULIC RESERVOIR REPAIR (CONT).

(2) Install reservoir (20) on bracket (17) with

two screws (16), screws (19), nuts (15) and

nuts (18). Tighten screws to 45 lb-ft 

(61 N.

m).

(3) Install preformed packing (5) on hose

2701 (4).

(4) Install hose 2701 (4) on tee (6).

(5) Install preformed packing (8) on hose

2286 (7).

(6) Install hose 2286 (7) on tee (6).

(7) Install preformed packing (10) on hose

2302 (9).

(8) Install hose 2302 (9) on elbow (11).

(9) Install preformed packing (13) on hose 2278

(12).

(10) Install hose 2278 (12) on elbow (14).
TM 9-2320-364-20-5

 14-55

(11) Install preformed packing (3) and hose

2553 (1) on elbow (2).

f. Follow-On Maintenance:

• Install left side noise panel, (Para 17-28).

• Fill steering reservoir, (Para 14-2).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

14-56 

Materials/Parts

Oil, Hydraulic (Item 50, Appendix C)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Pan, Drain (Item 47, Appendix G)

Removal Tool, Oil Filter (Item 54, Appendix G)

14-16. STEERING FILTER REPLACEMENT.

a. Removal.

Prolonged contact with lubricating oil (MIL-L-2104) may cause a skin rash. Skin and clothing 

that come in contact with lubricating oil should be thoroughly washed immediately. Saturated

clothing should be removed immediately. Areas in which lubricating oil is used should be well

ventilated to keep fumes to a minimum.

(1) Position drain pan under filter (1).

NOTE

• Preformed packing may stay on filter or housing.

• Filter is removed by turning counter-clockwise.

(2) Remove filter (1) and preformed packing (2) from housing (3). Discard preformed packing and filter.
TM 9-2320-364-20-5

 14-57

b. Installation.

(1) Coat preformed packing (2) with hydraulic

oil and install preformed packing in

housing (3).

(2) Fill filter (1) with hydraulic oil.

Tighten filter only 3/4 to 1 full

turn after filter contacts housing.

Failure to comply may result in

damage to equipment.

(3) Install filter (1) on housing (3). Tighten

filter 3/4 to 1 full turn.

c. Follow-On Maintenance:

• Fill steering reservoir, (Para 2-9, Lubrication Table 2-3).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

14-58 

Materials/Parts

Lockwasher (2) (Item 173, Appendix F)

Packing, Preformed (2) (Item 234, Appendix F)

Packing, Preformed (2) (Item 252, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Steering filter removed, (Para 14-16)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

Wrench, Combination 1-5/8 in.

(Item 84, Appendix G)

14-17. STEERING FILTER ADAPTER HEAD REPLACEMENT.

a. Removal.

NOTE

• Tag and mark all hydraulic hoses prior to removal.

• Cap and plug all hydraulic hoses to prevent contamination.

(1) Remove hose 2883 (1) and preformed packing (2) from elbow (3). Discard preformed packing.

(2) Remove hose 2553 (4) and preformed packing (5) from elbow (6). Discard preformed packing.
TM 9-2320-364-20-5

 14-59

NOTE

Note position of words “IN” and

“OUT” on top of steering filter

head.

(3) Loosen jam nuts (7) and (8) on elbows (3)

and (6).

(4) Remove two screws (9), lockwashers (10)

and steering filter head (11) from

bracket (12). Discard lockwashers.

NOTE

Note position of elbows prior to

removal.

(5) Remove elbow (3) and preformed

packing (13) from steering filter head (11).

Discard preformed packing.

(6) Remove elbow (6) and preformed

packing (14) from steering filter head (11).

Discard preformed packing.

b. Installation.

(1) Install preformed packing (14) on elbow (6).

(2) Install preformed packing (13) on elbow (3).

NOTE

Position elbows as noted prior to

removal.

(3) Position elbows (3) and (6) on steering filter

head (11).

NOTE

The word “OUT” on top of filter

head should face to rear of truck.

(4) Install steering filter head (11) on

bracket (12) with two lockwashers (10) and

screws (9).

(5) Tighten jam nuts (7) and (8) on elbows (3)

and (6).
TM 9-2320-364-20-5

14-60 

14-17. STEERING FILTER ADAPTER HEAD REPLACEMENT (CONT).

(6) Install preformed packing (5) and hose

2553 (4) on elbow (6).

(7) Install preformed packing (2) and hose

2883 (1) on elbow (3).

c. Follow-On Maintenance:

• Install steering filter, (Para 14-16).

• Start engine, (TM 9-2320-364-10).

• Check filter head for oil leaks, (TM 9-2320-364-10).

• Shut OFF engine, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 14-61

This task covers:

a. Torquing Procedure b. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0 to 237 N.

m])

(Item 95, Appendix G)

14-18. FRONT STEERING GEAR TORQUING PROCEDURE.

a. Torquing Procedure.

Stand clear of tires while turning.

Failure to do so may result in

injury or death to personnel.

Do not overtighten front steering

gear mounting screws. Failure to

comply may result in damage to

equipment.

NOTE

• Screws are referred to by the number that is listed in tightening sequence.

• Tightening sequence shown is facing mounting bracket side of front steering gear.

(1) With the aid of an assistant, Start engine (TM 9-2320-364-10) and turn the steering wheel until tires are in

a straight forward position.

(2) Shut OFF engine.

FRONT

STEERING

GEAR

FRONT STEERING GEAR

MOUNTING BRACKET
TM 9-2320-364-20-5

14-62 

14-18. FRONT STEERING GEAR TORQUING PROCEDURE (CONT).

(3) Tighten screw (1) then screw (2) on front steering gear and front steering gear bracket to 160 lb-ft to 170 lb-ft

(217 N.

m to 231 N.m).

Stand clear of tires while turning. Failure to do so may result in injury or death to personnel.

• Do not overtighten front steering gear mounting screws. Failure to comply may result in

damage to equipment.

• Do not hold front steering gear in relief for more than 30 seconds at a time. Failure to

comply may result in damage to equipment.

NOTE

• Screws are referred to by the number that is listed in tightening sequence.

• Tightening sequence shown is facing mounting bracket side of front steering gear.

• Front steering gear is in relief when steering wheel can no longer be turned and a hissing

sound is heard.

(4) With the aid of an assistant, Start engine and turn steering wheel completely to the left until front steering

gear goes into relief.

(5) Tighten screw (3) then screw (4) on front steering gear and front steering gear bracket to 160 lb-ft to 170

lb-ft (217 N.

m to 231 N.m).

(6) With the aid of an assistant, turn the steering wheel completely to the right until the front steering gear

goes into relief.

(7) Tighten screw (5) then screw (6) on front steering gear and front steering gear bracket to 160 lb-ft to 170

lb-ft (217 N.

m to 231 N.m).

(8) With the aid of an assistant, turn the steering wheel completely to the left until the front steering gear goes

into relief.

(9) Tighten screw (7) then screw (8) on front steering gear and front steering gear bracket to 160 lb-ft to 170

lb-ft (217 N.

m to 231 N.m).

FRONT

STEERING

GEAR

FRONT STEERING GEAR

MOUNTING BRACKET
TM 9-2320-364-20-5

 14-63/(14-64 blank)

(10) If any of the eight front steering gear screws were loose, Perform Steps (1) through (9) two additional

times.

(11) Shut OFF engine.

b. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

TM 9-2320-364-20-5

 15-1

CHAPTER 15

FRAME MAINTENANCE

Para Contents Page

15-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

15-2 Skid Plate Replacement 15-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-3 Skid Plate Structure Replacement 15-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-4 Skid Plate Crossmember Replacement 15-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-5 Cab Step Replacement 15-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-6 Front Tandem Crossmember Torquing Procedure 15-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-7 Air Dryer Bracket Replacement 15-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-8 Rear Hard Lift Assembly Replacement 15-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-9 Tread Platform Assembly Replacement 15-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-10 Platform Assembly Replacement (Model 1075 Only) 15-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-11 Rear Hard Lift Bracket Replacement 15-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-12 Axle Stop Replacement 15-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-13 Tie Down Ring Replacement 15-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-14 Service Gladhand Bracket Replacement 15-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-15 Horizontal Roller Replacement 15-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-16 Angled Roller Replacement 15-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-17 Rear Roller Assembly Replacement 15-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-18 Bumper Stop Bracket 15-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-19 Truck-To-Trailer LHS Electrical Connector Bracket Replacement 15-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-20 Self-Guided Coupler Repair 15-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-21 Spare Tire Carrier And Davit Replacement 15-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-22 Spare Tire Carrier Winch Replacement 15-69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-23 Spare Tire Carrier Wire Rope Replacement 15-71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-24 Auxiliary Fuel Tank Tread Platform Assembly Replacement 15-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15-1. INTRODUCTION.

This chapter contains maintenance instructions for removing, replacing, installing and adjusting components of the

frame as authorized by the Maintenance Allocation Chart (MAC) at the Unit Maintenance level.
TM 9-2320-364-20-5

15-2 

Materials/Parts

Locknut (9) (Item 96, Appendix F)

Lockwasher (4) (Item 195, Appendix F)

Screw, Self-Tapping (17) (Item 293, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Machine gun ring removed

(if equipped), (Para 22-2)

Machine gun ring front support removed

(if equipped), (Para 22-4)

Cab steps removed, (Para 15-5)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Lifting Device Minimum Capacity 200 lbs (91 kg)

15-2. SKID PLATE REPLACEMENT.

a. Removal.

(1) Remove two screws (1), lockwashers (2) and

skid plate window guard (3) from skid

plate (4). Discard lockwashers.

(2) Remove two screws (5), lockwashers (6) and

skid plate blackout lamp guard (7) from skid

plate (4). Discard lockwashers.
TM 9-2320-364-20-5

 15-3

Skid plate weighs 130 lbs (59 kg). Attach suitable lifting device prior to removal to prevent

injury to personnel.

Ensure lifting device is not attached to skidplate frame. Failure to comply may result in

damage to equipment.

(3) Attach lifting device to skid plate (4).

NOTE

Perform Step (4) if truck is not

equipped with machine gun ring.

Otherwise, go to Step (5).

(4) Remove four locknuts (8), screws (9) and

washers (10) from skid plate (4). Discard

locknuts.

(5) Remove five locknuts (11) and screws (12)

from bottom of skid plate (4). Discard

locknuts.

(6) Remove eight self-tapping screws (13) from sides of skid plate (4). Discard self-tapping screws.

(7) With the aid of an assistant, remove nine self-tapping screws (14) from top of skid plate (4). Discard selftapping screws.

(8) With the aid of an assistant, remove skid plate (4) from skid plate structure (15).

(9) Remove lifting device from skid plate (4).

b. Installation.

Skid plate weighs 130 lbs (59 kg). Attach suitable lifting device prior to installation to prevent

injury to personnel.

(1) Attach lifting device to skid plate (4).

(2) With the aid of an assistant, position skid plate (4) on skid plate structure (15).

(3) With the aid of an assistant, position nine self-tapping screws (14) in top of skid plate (4).

(4) With the aid of an assistant, position eight self-tapping screws (13) in sides of skid plate (4).

(5) With the aid of an assistant, install five screws (12) and locknuts (11) in bottom of skid plate (4).
TM 9-2320-364-20-5

15-4 

15-2. SKID PLATE REPLACEMENT (CONT).

(6) Tighten nine self-tapping screws (14) and

eight self-tapping screws (13).

(7) Remove lifting device from skid plate (4).

NOTE

Perform Step (8) if truck is not

equipped with machine gun ring.

(8) Install four washers (10), screws (9) and

locknuts (8) in skid plate (4).

(9) Install skid plate blackout lamp guard (7),

with two lockwashers (6) and screws (5) on

skid plate (4).

(10) Install skid plate window guard (3) with

two lockwashers (2) and screws (1) on skid

plate (4).

c. Follow-On Maintenance:

• Install machine gun front support (if equipped), (Para 22-4).

• Install machine gun ring (if equipped), (Para 22-2).

• Install cab steps, (Para 15-5).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 15-5

Materials/Parts

Locknut (2) (Item 92, Appendix F)

Locknut (4) (Item 96, Appendix F)

Locknut (2) (Item 140, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Weight classification sign removed, (Para 19-21)

Skid plate removed, (Para 15-2)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Lifting Device, Minimum Capacity 200 lbs

(90 kg)

15-3. SKID PLATE STRUCTURE REPLACEMENT.

a. Removal.

Skid plate structure weighs 95 

lbs (43 kg). Attach suitable 

lifting device prior to removal to

prevent injury to personnel.

(1) Attach lifting device to skid plate

structure (1).

(2) Remove two locknuts (2) and screws (3)

from bottom of skid plate structure (1).

Discard locknuts.

(3) Remove four locknuts (4) and screws (5)

from top of skid plate structure (1). Discard

locknuts.

(4) With the aid of an assistant, remove skid

plate structure (1) from truck (6).

(5) Remove lifting device from skid plate

structure (1).

(6) Remove four self-tapping screws (7) and two

brackets (8) from skid plate structure (1).
TM 9-2320-364-20-5

15-6 

15-3. SKID PLATE STRUCTURE REPLACEMENT (CONT).

b. Installation.

Skid plate structure weighs 95 

lbs (43 kg). Attach suitable 

lifting device prior to installation 

to prevent injury to personnel.

NOTE

Make sure bottom of skid plate

structure is installed on top of

cross member.

(1) Install two brackets (8) and four self-tapping

screws (7) on skid plate structure (1).

(2) Attach lifting device to skid plate

structure (1).

(3) With the aid of an assistant, position skid

plate structure (1) on truck (6).

(4) Position four screws (5) and locknuts (4) in

top of skid plate structure (1).

NOTE

• To ensure maximum

clearance between skid

plate structure and cab, pull

structure as far forward as

possible before tightening

locknuts.

• Ensure there is a minimum

of 3/8 inch (9.53 mm)

clearance between skid

plate and headlights.

(5) Position two screws (3) and locknuts (2) in

bottom of skid plate structure (1). With the

aid of an assistant, pull skid plate 

structure (1) forward and tighten locknuts.

(6) Tighten screws (5) and locknuts (4).
TM 9-2320-364-20-5

 15-7

c. Follow-On Maintenance:

• Install skid plate, (Para 15-2).

• Install weight classification sign, (Para 19-21).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

15-8 

Materials/Parts

Locknut (11) (Item 92, Appendix F)

Locknut (4) (Item 93, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Skid plate structure removed, (Para 15-3)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

15-4. SKID PLATE CROSSMEMBER REPLACEMENT.

a. Removal.

Skid plate crossmember weighs 55 lbs (25 kg). Attach suitable lifting device prior to removal

to prevent possible injury to personnel.

NOTE

Perform Step (1) if truck is equipped with self-recovery winch. Otherwise, go to Step (2).

(1) Remove three locknuts (1) and screws (2) from front self-recovery winch guide (3). Discard locknuts.
TM 9-2320-364-20-5

 15-9

(2) Remove four locknuts (4), screws (5) and

left and right brace assembly (6) from 

crossmember assembly (7). Discard

locknuts.

(3) With the aid of an assistant, remove four

locknuts (8), three screws (9), washers 

(10), screw (11), two spacers (12) and

crossmember assembly (7) from frame 

(13). Discard locknuts.

(4) Remove four locknuts (14), screws (15) 

and left and right brace assembly (6) 

from left and right frame (13). Discard

locknuts.

b. Installation.

Skid plate crossmember weighs

55 lbs (25 kg). Attach suitable

lifting device prior to installation 

to prevent possible injury to

personnel.

(1) Position four screws (15), left and right

brace assembly (6) and locknuts (14) on left

and right frame (13).

(2) With the aid of an assistant, install crossmember assembly (7) and two spacers (12)

with three screws (9), washers (10), screw

(11) and four locknuts (8).

(3) Position left and right brace assembly (6),

four screws (5) and locknuts (4) on crossmember assembly (7).

(4) Tighten locknuts (14) and (4).

14

11 4

5

15

6

8

8

12

12 7

10

13

9
TM 9-2320-364-20-5

15-10 

15-4. SKID PLATE CROSSMEMBER REPLACEMENT (CONT).

NOTE

Perform Step (5) if truck is

equipped with self-recovery

winch.

(5) Install three screws (2) and locknuts (1) in

front self-recovery winch guide (3).

c. Follow-On Maintenance:

• Install skid plate structure, (Para 15-3).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 15-11

Materials/Parts

Sealing Compound (Item 77, Appendix C)

Locknut (2) (Item 92, Appendix F)

Locknut (2) (Item 140, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

15-5. CAB STEP REPLACEMENT.

a. Removal.

NOTE

• Both cab steps are removed and disassembled the same way. Left side is shown.

• Rapid links are opened and closed by turning nut on rapid link.

(1) Open rapid link (1) on chain mount bracket (2) and chain (3).

(2) Remove rapid link (1) and chain (3) from chain mount bracket (2).

(3) Remove two locknuts (4), screws (5) and cab step assembly (6) from front cross member (7). Discard

locknuts.

1

5

6

2

4

3

7
TM 9-2320-364-20-5

15-12 

15-5. CAB STEP REPLACEMENT (CONT).

(4) Remove locknut (8), screw (9), chain (10), and

chain (3) from upper step (11). Discard locknut.

(5) Remove locknut (12), screw (13), two

washers (14), spacer (15), upper step (11)

and step support (16) from step link

assembly (17). Discard locknut.

(6) Open rapid link (18) on lower step assembly

(19).

(7) Remove rapid link (18) and chain (10) from

lower step assembly (19).

(8) Remove locknut (20), screw (21), two

washers (22), spacer (23) and step link

assembly (17) from lower step assembly

(19). Discard locknut. 18

19

23

21 10

22

17

22

20

10

17

8

9

11

3

16

14

12

14 15

13
TM 9-2320-364-20-5

 15-13

b. Installation.

NOTE

• Both cab steps are

assembled and installed the

same way. Left side shown.

• When properly installed,

step will slide freely on step

link.

(1) Install step link assembly (17), spacer (23),

two washers (22), screw (21) and

locknut (20) on lower step assembly (19).

Tighten locknut snug against washer until

step moves freely.

Adhesives, solvents, and sealing

compounds can burn easily, can 

give off harmful vapors, and are

harmful to skin and clothing. To 

avoid injury or death, keep away 

from open fire and use in wellventilated area. If adhesive, 

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and water.

NOTE

Chain installed on chain mount

bracket has 11 links. Chain

installed on lower step has 8

links.

(2) Apply sealing compound on threads of rapid

link (18) and install rapid link on chain (10)

and lower step assembly (19).

18

19

23

21 10

22

17

22

20
TM 9-2320-364-20-5

15-14 

15-5. CAB STEP REPLACEMENT (CONT).

(3) Install step support (16), upper step (11),

spacer (15), two washers (14), screw (13)

and locknut (12) on step link assembly (17).

Tighten locknut snug against washer until

upper step moves freely.

(4) Install chain (10), and chain (3) on upper

step (11) with screw (9) and locknut (8).

(5) Install cab step assembly (6), two screws (5)

and locknuts (4) on front cross member (7).

Adhesives, solvents, and sealing

compounds can burn easily, can 

give off harmful vapors, and are

harmful to skin and clothing. To 

avoid injury or death, keep away 

from open fire and use in wellventilated area. If adhesive, 

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and water.

(6) Apply sealing compound to threads of rapid

link (1) and install rapid link on chain (3)

and chain mount bracket (2).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

1

5

6

2

4

3

7

10

17

8

9

11

3

16

14

12

14 15

13
TM 9-2320-364-20-5

 15-15

This task covers:

a. Torquing Procedure b. Follow-on Maintenance

INITIAL SETUP

Personnel Required

Three

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/4 in. (Item 61, Appendix G)

Wrench, Combination 1-1/8 in.

(Item 79, Appendix G)

Adapter, Torque (Appendix D)

15-6. FRONT TANDEM CROSSMEMBER TORQUING PROCEDURE.

a. Torquing Procedure.

Torque wrench must be installed in straight line with torque adapter or improper torque may

be applied. Failure to comply may result in damage to equipment.

NOTE

• Both sides of front tandem crossmember are tightened the same way. Right side shown.

• Front tires may be turned as necessary to accommodate torque wrench.

(1) With the aid of assistants and using torque adapter, tighten two nuts (1) on crossmember (2) and gusset (3)

to 305 lb-ft (414 N.

m).

(2) With the aid of assistants and using torque adapter, tighten nut (4) on crossmember (2) and gusset (3) to

165 lb-ft (224 N.

m).
TM 9-2320-364-20-5

15-16 

15-6. FRONT TANDEM CROSSMEMBER TORQUING PROCEDURE (CONT).

(3) With the aid of an assistant, tighten four nuts

(1) on crossmember (2), crossmember (5)

and gusset (6).

(4) With the aid of an assistant, tighten two 

nuts (4) on crossmember (2), crossmember

(5) and gusset (6).

(5) With the aid of assistants and using torque

adapter, tighten two nuts (1) on crossmember

(5) and gusset (3) to 305 lb-ft (414 N.

m).

(6) With the aid of assistants and using torque

adapter, tighten nut (4) on crossmember (5)

and gusset (3) to 165 lb-ft (224 N.

m).

(7) Repeat Steps (1) through (6) for left side of

front tandem crossmember.

b. Follow-on Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 15-17

Materials/Parts

Locknuts (Item 93, Appendix F)

Locknuts (Item 133, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Air dryer guard removed (if equipped), (Para 12-19)

Air dryers and aftercooler removed, (Para 12-20)

Fuel/water separator and bracket removed, (Para 4-16)

Air dryer reservoir removed, (Para 12-35)

Coalescing filter assembly removed, (Para 12-23)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

15-7. AIR DRYER BRACKET REPLACEMENT.

a. Removal.

(1) Remove two locknuts (1), eight washers (2), four biscuits (3), and two screws (4) from air dryer mounting

bracket (5). Discard locknuts.

3

2 2

3

1

5

4
TM 9-2320-364-20-5

15-18 

15-7. AIR DRYER BRACKET REPLACEMENT (CONT).

NOTE

Trucks not equipped with crane

will have spacers behind bracket.

(2) With the aid of an assistant, remove four

locknuts (6), screws (7), spacer (8), spacer

(9) and air dryer mounting bracket (5) from

frame (10). Discard locknuts.

b. Installation.

(1) With the aid of an assistant, install air dryer

mounting bracket (5) on frame (10) with

four screws (7), spacer (8), spacer (9) and

locknuts (6).

(2) Install two screws (4), four biscuits (3), eight

washers (2), and two locknuts (1) on air

dryer mounting bracket (5). Tighten

locknuts until washer to washer

measurement is 1-5/16 inches (33mm).

c. Follow-On Maintenance:

• Install air dryer reservoir, (Para 12-35).

• Install fuel/water separator and bracket, (Para 4-16).

• Install air dryers and aftercooler, (Para 12-20).

• Install coalescing filter assembly, (Para 12-23).

• Install air dryer guard (if equipped), (Para 12-19).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

3

2 2

3

1

5

4

7

9

8

6

10

5

7
TM 9-2320-364-20-5

 15-19

Materials/Parts

Locknut (6) (Item 92, Appendix F)

Locknut (2) (Item 92, Appendix F) (if equipped

with CHU)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

CHU long strut bracket assembly removed 

(if equipped), (Para 21-33)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/4 in. (Item 61, Appendix G)

15-8. REAR HARD LIFT ASSEMBLY REPLACEMENT.

Materials/Parts

Locknut (6) (Item 140, Appendix F) (if not 

equipped with CHU)

Lockwasher (4) (Item 168, Appendix F)

a. Removal.

(1) Remove two tie down straps (1) from left hand extension assembly (2) and right hand extension 

assembly (3).

(2) Remove two screws (4), screws (5), four lockwashers (6) and washers (7) from extension assemblies 

(2) and (3). Discard lockwashers.

Right hand and left hand extension assemblies weigh 110 lb (50 kg) each. Use the aid of an

assistant when lifting to prevent injury to personnel.

(3) With the aid of an assistant, remove left hand extension assembly (2) and right hand extension assembly 

(3) from deck assembly (8).
TM 9-2320-364-20-5

15-20 

15-8. REAR HARD LIFT ASSEMBLY REPLACEMENT (CONT).

NOTE

• Perform Steps (4) and (5)

for trucks not equipped

with CHU.

• Perform Steps (6) through

(11) for trucks equipped

with CHU.

(4) Remove two quick disconnect pins (9),

pins (10) and left strut assembly (11) from

left collar bracket assembly (12) and hard lift

support bracket (13).

(5) Remove two quick disconnect pins (9),

pins (10) and right strut assembly (14) from

right collar bracket assembly (15) and hard

lift support bracket (13).
TM 9-2320-364-20-5

 15-21

(6) Remove quick disconnect pin (16), pin (17)

and left strut assembly (11) from left collar

bracket assembly (12).

(7) Remove quick disconnect pin (18), pin (19)

and hard lift slider bracket (20) from hard lift

support bracket (13).

NOTE

Perform Step (8) only if snapper

pin and/or wire is damaged.

(8) Remove snapper pin (21), wire (22) and

swaging sleeve (23) from hard lift slider

bracket (20) and pin (19).

(9) Remove quick disconnect pin (24) and pin

(25) from left strut assembly (11).

(10) Separate rear hard lift strut (26) and front

hard lift strut (27).

(11) Repeat Steps (6) through (10) for right strut

assembly.

NOTE

Left and right brackets are

different on trucks equipped with

CHU, however, removal

procedures are identical.

(12) With the aid of an assistant, remove six

locknuts (28), screws (29) and deck

assembly (8) from left bracket (30) and right

bracket (31). Discard locknuts.

NOTE

• Perform Steps (13) and (14)

for trucks not equipped

with CHU.

• Perform Steps (15) and (16)

for trucks equipped with

CHU.

(13) With the aid of an assistant, remove three

locknuts (32), screws (33) and left bracket (30)

from frame (34). Discard locknuts.

(14) With the aid of an assistant, remove three

locknuts (32), screws (33) and right

bracket (31) from frame (34).

(15) With the aid of an assistant, remove locknut

(32), screw (33) and left bracket (30) from

frame (34). Discard locknut.

(16) With the aid of an assistant, remove locknut

(32), screw (33) and right bracket (31) from

frame (34). Discard locknut.

18

19

23

13 22

25 26 11

16

24

17

12

21

20

27
TM 9-2320-364-20-5

15-22 

15-8. REAR HARD LIFT ASSEMBLY REPLACEMENT (CONT).

b. Installation.

NOTE

• Left and right brackets are

different on trucks equipped

with CHU, however,

installation procedures are

identical.

• Perform Steps (1) and (2)

for trucks not equipped

with CHU.

• Perform Steps (3) and (6)

for trucks equipped with

CHU.

(1) Install right bracket (31) on frame (34) with

three screws (33) and locknuts (32).

(2) Install left bracket (30) on frame (34) with

three screws (33) and locknuts (32).

(3) Install right bracket (31) on frame (34) with

screw (33) and locknut (32) in rear position.

Do not tighten.

(4) Install left bracket (30) on frame (34) with

screw (33) and locknut (32) in rear position.

Do not tighten.

(5) Install long strut bracket assembly, (Para

21-33).

(6) Tighten two locknuts (32).

(7) Install deck assembly (8) on left bracket (30)

and right bracket (31) with six screws (29)

and locknuts (28).

NOTE

• Perform Steps (8) and (9)

for trucks not equipped

with CHU.

• Perform Steps (10) through

(15) for trucks equipped

with CHU.

(8) Install left strut assembly (11), two pins (10)

and quick disconnect pins (9) on left collar

bracket assembly (12) and hard lift support

bracket (13).
TM 9-2320-364-20-5

 15-23

(9) Install right strut assembly (14), two pins

(10) and quick disconnect pins (9) on collar

bracket assembly (15) and hard lift support

bracket (13).

(10) Assemble front hard lift strut (27) and rear

hard lift strut (26) with pin (25) and quick

disconnect pin (24).

(11) Install pin (17), quick disconnect pin (16)

and left strut assembly (11) on left collar

bracket assembly (12).

(12) Install pin (19), quick disconnect pin (18)

and hard lift slider bracket (20) on hard lift

support bracket (13).

(13) Attach snapper pin (21) to pin (19) by

positioning wire (22) through hole in hard

lift slider bracket (20).

(14) Position wire (22) through swaging sleeve

(23), pin (19) and loop back to swaging

sleeve and crimp.

(15) Repeat steps (10) through (14) for right

strut assembly.

18

19

23

13 22

25 26 11

16

24

17

12

21

20

27
TM 9-2320-364-20-5

15-24 

15-8. REAR HARD LIFT ASSEMBLY REPLACEMENT (CONT).

(16) With the aid of an assistant, position left

hand extension assembly (2) and right hand

extension assembly (3) on deck assembly

(8).

(17) Install two screws (5), screws (4), four

lockwashers (6) and washers (7) in

extension assemblies (2) and (3). Tighten

screws (4) and (5) to 23 lb-ft (31 N.

m).

(18) Install and tighten two tie down straps (1)

securing left hand extension assembly (2)

and right hand extension assembly (3).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 15-25

Materials/Parts

Locknut (4) (Item 93, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

15-9. TREAD PLATFORM ASSEMBLY REPLACEMENT.

a. Removal.

(1) Remove four screws (1), locknuts (2) and tread platform assembly (3) from mounting straps (4). Discard

locknuts.

(2) Remove quickedge molding (5) from tread platform assembly (3).

b. Installation.

(1) Install quickedge molding (5) on tread platform assembly (3).

(2) Install tread platform assembly (3), four screws (1) and locknuts (2) on mounting strips (4).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

15-26 

Materials/Parts

Locknut (4) (Item 93, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Lifting Device, Minimum capacity 100 lbs

(45 kg)

15-10. PLATFORM ASSEMBLY REPLACEMENT (MODEL 1075 ONLY).

a. Removal.

(1) Remove four locknuts (1) and screws (2) from legs (3) and (4). Discard locknuts.

Platform assembly weighs 62 lbs (28 kg). Attach suitable lifting device prior to removal to

prevent possible injury to personnel.

(2) With the aid of an assistant, remove platform assembly (5) from mounting frame (6).

(3) Remove four locknuts (7), washer (8), springs (9), washer (8), screws (10) and legs (3) and (4) from

platform assembly (5). Discard locknuts.
TM 9-2320-364-20-5

 15-27

b. Installation.

(1) Position legs (3) and (4) on platform

assembly (5) with four screws (10), washers

(8), springs (9), washers (8) and locknuts

(7).

NOTE

Locknut should be tightened until

there is 2.5 in. (6.4 cm) between

inner edge of platform assembly

and outer edge of locknut.

(2) Tighten four locknuts (7) on screws (10).

Platform assembly weighs 62 lbs

(28 kg). Attach suitable lifting

device prior to installation to

prevent possible injury to

personnel.

(3) With the aid of an assistant, position

platform assembly (5) on mounting frame

(6).

(4) Install four screws (2) and locknuts (1) on

legs (3) and (4).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

15-28 

Materials/Parts

Locknut (36) (Item 92, Appendix F)

Locknut (4) (Item 144, Appendix F)

Lockwasher (Item 168, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Rear hard lift assembly removed, (Para 15-8)

Load sensing valves removed, (Para 12-33)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Multiplier, Torque (Item 45, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0 to 237 N.

m])

(Item 95, Appendix G)

Lifting Device, Minimum Capacity 110 lb

(50 kg)

15-11. REAR HARD LIFT BRACKET REPLACEMENT.

a. Removal.

(1) Remove twelve locknuts (1), screws (2) and crossmember (3) from right and left hard lift brackets (4).

Discard locknuts.
TM 9-2320-364-20-5

 15-29

(2) Remove two quick release pins (5) and two

pins (6) from crossover tube (7).

Crossover tube weighs 100 lbs

(45 kg). Attach a suitable lifting

device prior to removal to prevent

possible injury to personnel.

(3) Attach lifting device to crossover tube (7).

(4) Remove eight locknuts (8), screws (9) and

crossover tube (7) from right and left hard

lift brackets (4). Discard locknuts.

(5) Remove nut (10), lockwasher (11) and

screw (12) from steering arm (13). Discard

lockwasher.

(6) Pry drag link (14) from steering arm (13).
TM 9-2320-364-20-5

15-30 

15-11. REAR HARD LIFT BRACKET REPLACEMENT (CONT).

(7) Remove two quick release pins (15) and two

pins (16) from right and left hard lift

brackets (4).

(8) Remove four locknuts (17) and screws (18)

from right and left hard lift brackets (4).

Discard locknuts.

(9) Remove six locknuts (19) and screws (20)

from right and left hard lift brackets (4).

Discard locknuts.

Each hard lift bracket weighs 67

lbs (30 kg). Attach a suitable

lifting device prior to removal to

prevent possible injury to

personnel.

(10) Attach lifting device to each hard lift

bracket (4), one at a time.

(11) Remove ten locknuts (19), screws (21) and right and left hard lift brackets (4) from frame (22). Discard

locknuts.

b. Installation.

Each hard lift bracket weighs 67 lbs (30 kg). Attach a suitable lifting device prior to

installation to prevent possible injury to personnel.

(1) Attach lifting device to each hard lift bracket (4), one at a time.

(2) Install each hard lift bracket (4) on frame (22) with ten screws (21) and locknuts (19). Tighten locknuts

hand tight.

(3) Install six screws (20) in right and left hard lift brackets (4) and frame (22) with six locknuts (19). Tighten

locknuts hand tight.

(4) Install four screws (18) in right and left hard lift brackets (4) and frame (22) with four locknuts (17).

Tighten locknuts to 210 lb-ft (285 N.

m).

(5) Tighten sixteen locknuts (19) to 375 lb-ft (508 N.

m).

(6) Install two pins (16) in right and left hard lift bracket (4) with two quick release pins (15).
TM 9-2320-364-20-5

 15-31

(7) Install drag link (14) on steering arm (13)

with screw (12), lockwasher (11) and

nut (10).

Crossover tube weighs 100 lbs

(45 kg). Attach a suitable lifting

device prior to installation to

prevent possible injury to

personnel.

(8) Attach lifting device to crossover tube (7).

(9) Install crossover tube (7) in right and left

hard lift brackets (4) with eight screws (9)

and locknuts (8). Tighten locknuts to

375 lb-ft (508 N.

m).

(10) Install two pins (6) in crossover tube (7) with

two quick release pins (5).

Ensure larger radius cut-out on

crossmember is positioned

towards rear of truck or damage

to equipment may result.

(11) Install crossmember (3) between right and

left hard lift brackets (4) with twelve

screws (2) and locknuts (1). Tighten

locknuts to 375 lb-ft (508 N.

m).

c. Follow-On Maintenance:

• Install load sensing valves, (Para 12-33).

• Install rear hard lift assembly, (Para 15-8).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

15-32 

Materials/Parts

Locknut (2) (Item 112, Appendix F)

This task covers:

a. Axle No. 1, 2 and 4 Right Hand Side d. Axle No. 5 Right and Left Hand Side

b. Axle No. 1, 2 and 4 Left Hand Side e. Follow-On Maintenance

c. Axle No. 3 Right and Left Hand Side

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

15-12. AXLE STOP REPLACEMENT.

a. Axle No. 1, 2 and 4 Right Hand Side.

(1) Removal.

(a) Remove two locknuts (1), screws (2) and axle stop bracket (3) from truck (4). Discard locknuts.

(b) Remove screw (5) and axle stop (6) from axle stop bracket (3).

(2) Installation.

(a) Install axle stop (6) and screw (5) on axle stop bracket (3).

NOTE

Position axle stop bracket tight on frame of truck.

(b) Install axle stop bracket (3), two screws (2) and locknuts (1) on truck (4).
TM 9-2320-364-20-5

 15-33

b. Axle No. 1, 2 and 4 Left Hand Side.

(1) Removal.

(a) Remove two locknuts (1), screws (2) and axle stop bracket (3) from truck (4). Discard locknuts.

(b) Remove screw (5) and axle stop (6) from axle stop bracket (3).

(2) Installation.

(a) Install axle stop (6) and screw (5) on axle stop bracket (3).

NOTE

Position axle stop bracket tight to frame of truck.

(b) Install axle stop bracket (3), two screws (2) and locknuts (1) on truck (4).
TM 9-2320-364-20-5

15-34 

15-12. AXLE STOP REPLACEMENT (CONT).

c. Axle No. 3 Right and Left Hand Side.

(1) Removal.

(a) Remove four locknuts (1), screws (2) and axle stop bracket (3) from truck (4). Discard locknuts.

(b) Remove screw (5) and axle stop (6) from axle stop bracket (3).

(2) Installation.

(a) Install axle stop (6) and screw (5) on stop bracket (3).

(b) Install axle stop bracket (3), four screws (2) and locknuts (1) on truck (4).
TM 9-2320-364-20-5

 15-35

d. Axle No. 5 Right and Left Sides.

(1) Removal.

(a) Remove two locknuts (1), screws (2) and axle stop bracket (3) from truck (4). Discard locknuts.

(b) Remove screw (5) and axle stop (6) from axle stop bracket (3).

(2) Installation.

(a) Install axle stop (6) and screw (5) on axle stop bracket (3).

NOTE

Position stop bracket tight to frame of truck.

(b) Install axle stop bracket (3), two screws (2) and locknuts (1) on truck (4).

e. Follow-on Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

15-36 

Materials/Parts

Locknut (4) (Item 92, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine Off, (TM 9-2320-364-10)

Wheels Chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

15-13. TIE DOWN RING REPLACEMENT.

a. Removal.

NOTE

There are six tie down rings. The

front right and left are removed at

direct support. The remaining

four are all removed the same

way with the exception of one

which also has a valve bracket.

The one with the valve bracket is

shown.

(1) Remove bolt ring (1) from rectangular plain

nut (2).

(2) Remove four locknuts (3), screws (4) and

rectangular plain nut (2) from frame (5) and

bracket (6). Discard locknuts.

b. Installation.

(1) Install rectangular plain nut (2) on bracket

(6) and frame (5) with four screws (4) and

locknuts (3).

(2) Install bolt ring (1) on rectangular plain nut (2).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

1

2

5

4

3

6
TM 9-2320-364-20-5

 15-37

Materials/Parts

Adhesive (Item 8, Appendix C),

(Model A connector only)

Cable Ties (Item 25, Appendix C)

Locknut (5) (Item 91, Appendix F)

Locknut (2) (Item 107, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Gladhand removed, (Para 12-43)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

15-14. SERVICE GLADHAND BRACKET REPLACEMENT.

Materials/Parts - Continued

Locknut (2) (Item 140, Appendix F)

a. Removal.

NOTE

• There are two types of 7-pin electrical connectors. Model B replaced Model A.

• Model A has a rubber boot covering the back.

• Model B uses rubber push on connectors on the back.

• Perform Step (1) for Model A connector.

(1) Remove cable tie (1) and slide boot (2) back on chassis wire harness (3).

(2) Remove two locknuts (4) and screws (5) from MC16 connector (6) and bracket (7). Discard locknuts.

(3) Pull MC16 connector (6) toward rear of truck and guide chassis wire harness (3) down through slot on

bracket (7).

(4) Remove four locknuts (8), screws (9), connector cover (10) and two spacers (11) from MC15 connector

(12) and bracket (7). Discard locknuts.

(5) Pull MC15 connector (12) toward rear of truck and guide wires (13) through slot on side of bracket (7).
TM 9-2320-364-20-5

15-38 

15-14. SERVICE GLADHAND BRACKET REPLACEMENT (CONT).

(6) Remove locknut (14), cushion clip (15) and

screw (16) from bracket (7). Discard

locknut.

NOTE

Perform Step (7) if name plate is

damaged.

(7) Remove two drive screws (17) and

nameplate (18) from bracket (7).

(8) With the aid of an assistant, remove two

locknuts (19), screws (20) and bracket (7)

from rear crossmember (21). Discard

locknuts.

b. Installation.

(1) With the aid of an assistant, install

bracket (7) on rear crossmember (21) with

two screws (20) and locknuts (19).

NOTE

Perform Step (2) if name plate

was removed.

(2) Install nameplate (18) on bracket (7) with

two drive screws (17).

(3) Install cushion clip (15) on rear of

bracket (7) with screw (16) and locknut (14).

(4) Guide wires (13) on MC15 connector (12)

through slot on side of bracket (7).

(5) Install two spacers (11), MC15 connector

(12) and connector cover (10) on bracket (7)

with four screws (9) and locknuts (8).

(6) Guide wires (3) on MC16 connector (6)

through slot on bottom of bracket (7).

(7) Install MC16 connector (6) on bracket (7)

with two screws (5) and locknuts (4).
TM 9-2320-364-20-5

 15-39

Adhesives, solvents and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

NOTE

Perform Steps (8) through (10)

for Model A connector.

(8) Apply a thin strip of adhesive completely

around rear of MC16 connector (6).

(9) Install boot (2) on MC16 connector (6) with

cable tie (1).

(10) Apply a thin strip of adhesive to rear of boot

(2) where wires (3) enter boot (2).

c. Follow-On Maintenance:

• Install gladhand, (Para 12-43).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

15-40 

Materials/Parts

Lockwasher (2) (Item 180, Appendix F)

Lockwasher (Item 211, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Angled rollers removed, (Para 15-16)

Rear roller assembly removed, (Para 15-17)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Lifting Device, Minimum Capacity 375 lbs

(170 kg)

15-15. HORIZONTAL ROLLER REPLACEMENT.

a. Removal.

Rear roller assembly weighs 375

lbs (170 kg). Attach suitable 

lifting device prior to removal to

prevent possible injury to

personnel.

NOTE

Both right and left hand

horizontal rollers are removed 

the same way. Right horizontal

roller is shown.

(1) Using lifting device, place rear roller

assembly (1) on clean work surface.
TM 9-2320-364-20-5

 15-41

(2) Remove lube fitting (2), bend lockwasher

tab out of nut slot and remove nut (3),

lockwasher (4) and thrust washer (5) from

roller (6) at underside of roller assembly (1).

Discard lockwasher.

NOTE

Lockplate looks different on

trucks equipped with CHU,

however, procedures are identical.

(3) Remove two screws (7), lockwashers (8),

lockplate (9) and lube fitting (10) from roller

assembly (1). Discard lockwashers.

(4) Attach lifting device to rear roller (6).

Horizontal roller weighs 75 lbs

(34 kg). Attach suitable lifting

device prior to removal to 

prevent possible injury to

personnel.

(5) Using lifting device, remove roller (6) from

roller assembly (1).

(6) Remove lifting device.
TM 9-2320-364-20-5

15-42 

15-15. HORIZONTAL ROLLER REPLACEMENT (CONT).

b. Installation.

(1) Attach lifting device to roller (6).

Horizontal roller weighs 75 lbs

(34 kg). Attach suitable lifting

device prior to installation to

prevent possible injury to

personnel.

(2) Using lifting device, position roller (6) in

roller assembly (1).

NOTE

Lockplate looks different on

trucks equipped with CHU,

however, procedures are identical.

(3) Install lockplate (9), lockwasher (8),

screw (7) and lube fitting (10) in roller

assembly (1).
TM 9-2320-364-20-5

 15-43

NOTE

Nut is installed properly when nut

is tightened and roller does not

bind.

(4) Install thrust washer (5), lockwasher (4), nut

(3) and lube fitting (2) on roller (6). Tighten

nut. Bend lockwasher tab into nut slot.

(5) Bend tab of lockwasher (4) into slot of

nut (3).

(6) Remove lifting device from roller (6).

c. Follow-On Maintenance:

• Install rear roller assembly, (Para 15-17).

• Install angled rollers, (Para 15-16).

• Lubricate roller assembly, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

15-44 

Materials/Parts

Lockwasher (4) (Item 173, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Hammer, Soft Faced (Item 33, Appendix G)

15-16. ANGLED ROLLER REPLACEMENT.

Materials/Parts - Continued

Lockwasher (2) (Item 180, Appendix F)

Lockwasher (Item 211, Appendix F)

a. Removal.

(1) Remove lube fitting (1).

NOTE

Both left and right hand angled rollers are removed the same way. Left hand roller is shown.

(2) Bend tab of lockwasher (2) out of nut (3) slot.

(3) Remove nut (3) and lockwasher (2). Discard lockwasher.
TM 9-2320-364-20-5

 15-45

NOTE

Bracket looks different on trucks

equipped with CHU, however,

procedures are identical.

(4) Remove lube fitting (4), two screws (5),

lockwashers (6), bracket (7), lockplate (8),

four screws (9), lockwashers (10) and

endplate (11). Discard lockwashers.

(5) Using a soft faced hammer, remove roller

(12) from roller assembly (13).

b. Installation.

(1) Position roller (12) in roller assembly (13).

(2) Install endplate (11), four lockwashers (10)

and screws (9).

NOTE

Bracket looks different on trucks

equipped with CHU, however,

procedures are identical.

(3) Install lockplate (8), bracket (7), two

lockwashers (6) and screws (5).

(4) Install lube fitting (4) in roller

assembly (13).
TM 9-2320-364-20-5

15-46 

15-16. ANGLED ROLLER REPLACEMENT (CONT).

(5) Install lockwasher (2), nut (3) and grease

fitting (1). Tighten nut.

(6) Bend tab of lockwasher (2) into slot of nut

(3).

c. Follow-On Maintenance:

• Lubricate rear rollers, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 15-47

Materials/Parts

Sealing Compound (Item 77, Appendix C)

Locknut (6) (Item 93, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Multiplier, Torque (Item 45, Appendix G)

Socket Set, 3/4 in. (Item 61, Appendix G)

Wrench, Combination 1-1/8

(Item 79, Appendix G)

Lifting Device, Minimum Capacity 375 lbs

(170 kg)

15-17. REAR ROLLER ASSEMBLY REPLACEMENT.

a. Removal.

Rear roller assembly weighs 375 lbs (170 kg). Attach suitable lifting device prior to removal

or installation to prevent possible injury to personnel.

(1) Attach lifting device to rear roller assembly (1).

(2) Remove six locknuts (2), four screws (3) and two screws (4) from rear roller assembly (1). Discard

locknuts.
TM 9-2320-364-20-5

15-48 

15-17. REAR ROLLER ASSEMBLY REPLACEMENT (CONT).

To remove or install rear roller

assembly, it is necessary to slide 

the assembly under rear marker

light bracket. Be careful not to

damage marker light wiring.

(3) With the aid of an assistant, guide rear roller

assembly (1) up and off of truck.

(4) Remove lifting device from rear roller

assembly (1).

b. Installation.

Rear roller assembly weighs 375

lbs (170 kg). Attach suitable

lifting device prior to removal or

installation to prevent possible

injury to personnel.

(1) Attach lifting device to rear

roller assembly (1).

To remove or install rear roller

assembly, it is necessary to slide

the assembly under rear marker

light bracket. Be careful not to

damage marker light wiring.

(2) With the aid of an assistant, lower rear roller

assembly (1) onto truck.
TM 9-2320-364-20-5

 15-49

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and 

are harmful to skin and clothing.

To avoid injury or death, keep 

away from open fire and use in a

well-ventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(3) Coat threads of four screws (3) and two

screws (4) with sealing compound.

(4) Install four screws (3), two screws (4) and

six locknuts (2) in rear roller assembly (1).

(5) Remove lifting device from rear roller

assembly (1).

c. Follow-On Maintenance:

• Lubricate rollers, (Para 2-9).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

15-50 

Materials/Parts

Locknut (6) (Item 91, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Reverse light removed, (Para 7-50)

Rear hard lift extension assemblies removed,

(Para 15-8)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

15-18. BUMPER STOP BRACKET REPLACEMENT.

a. Removal.

(1) With the aid of an assistant, remove two locknuts (1) and screws (2) from outside corners of bumper stop

bracket (3). Discard locknuts.

(2) Remove three locknuts (1) and screws (4) from bumper stop bracket (3). Discard locknuts.

(3) With the aid of an assistant, remove locknut (1), bracket (5), screw (6) and bumper stop bracket (3) from

rear crossmember (7). Discard locknut.
TM 9-2320-364-20-5

 15-51

b. Installation.

(1) With the aid of an assistant, position bumper

stop bracket (3) on top of rear

crossmember (7).

(2) Position screw (6) in bumper stop

bracket (3) and bracket (5) with locknut (1).

(3) Position three screws (4) in bumper stop

bracket (3) and rear crossmember (7) with

locknuts (1).

(4) Install two screws (2) and locknuts (1) in

bumper stop bracket (3).

(5) Tighten locknut (1) on screw (6).

(6) Tighten three locknuts (1) on screws (4).

c. Follow-On Maintenance:

• Install rear hard lift extension assemblies, (Para 15-8).

• Install reverse light, (Para 7-50).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

15-52 

Materials/Parts

Locknut (2) (Item 91, Appendix F)

Locknut (Item 104, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

15-19. TRUCK-TO-TRAILER LHS ELECTRICAL CONNECTOR BRACKET

REPLACEMENT.

a. Removal.

(1) Remove connector cover (1) from MC30 connector (2).

(2) Remove four screws (3) and MC30 connector (2) from bracket (4).

(3) Remove locknut (5), screw (3) and cover chain (6) from bracket (4). Discard locknut.

(4) Remove two locknuts (7), screws (8) and bracket (4) from rear crossmember (9). Discard locknuts.

b. Installation.

(1) Install bracket (4) on rear crossmember (9) with two screws (8) and locknuts (7).

(2) Install cover chain (6) on bracket (4) with screw (3) and locknut (5).

(3) Install MC30 connector (2) in bracket (4) with four screws (3).

(4) Install connector cover (1) on MC30 connector (2).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 15-53

Materials/Parts

Locknut (5) (Item 146, Appendix F)

Pin, Cotter (Item 269, Appendix F)

Pin, Cotter (Item 278, Appendix F)

Pin, Roll (Item 280, Appendix F)

Pin, Roll (Item 281, Appendix F)

Pin, Roll (Item 282, Appendix F)

Pin, Roll (Item 283, Appendix F)

Pin, Roll (Item 284, Appendix F)

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Airblow (Item 31, Appendix G)

Socket Set, 3/4 in. (Item 61, Appendix G)

Socket, Wheel Bearing Adjustment Nut 3-1/4 in.

(Item 63, Appendix G)

Wrench, Combination (Item 87, Appendix G)

Torque Wrench (0 to 600 lb-ft [0 to 814 N.

m])

(Item 97, Appendix G)

Lifting Device, Minimum Capacity 100 lb (45 kg)

15-20. SELF-GUIDED COUPLER REPAIR.

a. Removal.

Self-guided coupler weighs 100 lbs (45 kg). Attach suitable lifting device prior to removal to

prevent possible injury to personnel.

(1) Attach lifting device to self-guided coupler (1).

(2) Remove hose clamp (2) and boot (3) from self-guided coupler (1).

(3) Remove cotter pin (4), nut (5) and washer (6) from self-guided coupler (1). Discard cotter pin.

(4) Remove self-guided coupler (1) from sleeve (7).
TM 9-2320-364-20-5

15-54 

15-20. SELF-GUIDED COUPLER REPAIR (CONT).

Ensure sleeve is fully supported

upon removal of four nuts, 

washers and screws or sleeve 

may fall and damage to parts 

may occur.

(5) With the aid of an assistant, remove four

nuts (8), washers (9), screws (10) and

sleeve (7) from truck (11).

b. Disassembly.

(1) Lift up locking gate (1) on coupler (2).

(2) Pull locking lever (3) out and pull lever (4)

back at same time to open coupler jaw (5).

(3) Remove cotter pin (6), nut (7), screw (8) and

coupler jaw (5) from coupler (2). Discard

cotter pin.

(4) Remove lube fitting cover (9) and lube

fitting (10) from screw (8).

5

7

2

8

10 9

6
TM 9-2320-364-20-5

 15-55

(5) Remove five locknuts (11), four screws (12),

screw (13) and shank (14) from coupler (2).

Discard locknuts.

(6) Remove roll pin (15), and locking gate (1)

from coupler (2). Discard roll pin.

(7) Remove nut (16), pull lever (4) and roll pin

(17) from latch pin (18). Discard roll pin.

Use care when removing springs. Springs are under tension and can act as projectiles when

released and could cause injury to personnel.

(8) Remove latch pin (18), latch (19) and spring (20) from coupler (2).

(9) Remove roll pin (21) and key (22) from latch (19). Discard roll pin.

(10) Remove roll pin (23) from locking lever (3). Discard roll pin.

(11) Remove locking lever (3), pivot pin (24) and spring (25) from coupler (2).

(12) Remove roll pin (26), pin (27) and spring (28) from coupler (2). Discard roll pin.

(13) Remove two lube fittings (29) from coupler (2).
TM 9-2320-364-20-5

15-56 

15-20. SELF-GUIDED COUPLER REPAIR (CONT).

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc).

Failure to comply may result in injury or death to personnel.

(1) Clean excess grease from coupler using drycleaning solvent and a cleaning cloth.

(2) Clean all parts in drycleaning solvent.

(3) Dry components with compressed air.

(4) Inspect all components with machined surfaces for scratches, cracks, gouges and stripped threads.

(5) Replace damaged components.
TM 9-2320-364-20-5

 15-57

d. Assembly.

(1) Install two lube fittings (29) on coupler (2).

Use extreme care when compressing, releasing, removing or installing springs. Springs are

under tension and can act as projectiles when released. Ensure proper eye protection is worn

to prevent injury to personnel.

(2) Position spring (28) and pin (27) on coupler (2).

(3) Install roll pin (26) in pin (27).

(4) Position spring (25) and pivot pin (24) on coupler (2).

(5) Position locking lever (3) on pivot pin (24) and install roll pin (23).

(6) Install roll pin (21) and key (22) on latch (19).

(7) Position spring (20) latch (19) and latch pin (18) on coupler (2).

(8) Position pull lever (4) on latch pin (18) and install nut (16).

(9) Install roll pin (17) on latch pin (18).

(10) Position locking gate (1) on coupler (2) and

install roll pin (15).

(11) Position shank (14), on coupler (2) and

install four screws (12), screw (13) and five

locknuts (11). Tighten locknuts (11) to 210

lb-ft (285 N.

m).
TM 9-2320-364-20-5

15-58 

15-20. SELF-GUIDED COUPLER REPAIR (CONT).

(12) Install lube fitting (10) in screw (8).

(13) Install lube fitting cover (9) on lube fitting

(10).

(14) Install coupler jaw (5) on coupler (2) using

screw (8) and nut (7).

NOTE

Nut in Step (15) is properly

installed when coupler jaw can

rotate freely.

(15) Tighten nut (7) on screw (8) until nut (7)

contacts coupler (2).

(16) Back off nut (7) to nearest slot and install

cotter pin (6).

e. Installation.

Ensure sleeve is fully supported

until after Step (2) is completed

or sleeve may fall. Failure to

comply may result in damage to

parts.

(1) With the aid of an assistant, position sleeve

(7) on truck (11).

(2) With the aid of an assistant, install four

screws (10), washers (9) and nuts (8) in

sleeve (7). Tighten nut to 500 lb-ft (678

N.

m).

5

7

2

8

10 9

6
TM 9-2320-364-20-5

 15-59

Self-guided coupler weighs 100 

lbs (45 kg). Attach suitable

lifting device prior to installation

to prevent possible injury to

personnel.

(3) Attach lifting device to self-guided 

coupler (1).

(4) Position self-guided coupler (1) on 

sleeve (7).

(5) Install washer (6) and nut (5) in self-guided

coupler (1).

(6) Tighten nut (5) to 100 lb-ft (136 N.

m).

(7) Back off nut (5) to nearest slot and install

cotter pin (4).

(8) Remove lifting device from self-guided

coupler (1).

NOTE

If thickness of washer behind nut

is less than 0.19 inch when Steps

(6) and (7) are repeated, replace

washer.

(9) Check that axial clearance does not exceed

1/32 inch. If clearance exceeds 1/32 inch,

remove cotter pin (4) and repeat Steps (6)

and (7).

(10) Install boot (3) and hose clamp (2) on

self-guided coupler (1).

f. Follow-On Maintenance:

• Lubricate self-guided coupler, (Para 2-9).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

15-60 

Materials/Parts

Grease (Item 42, Appendix C)

Locknut (9) (Item 91, Appendix F)

Locknut (4) (Item 122, Appendix F)

Pin, Cotter (4) (Item 273, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Spare tire removed, (TM 9-2320-364-10)

Spare tire carrier wire rope removed,

(Para 15-23)

Right-side work lamp removed, (Para 7-55)

Right-side noise panel removed, (Para 17-26)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Lifting Device, Minimum Capacity 150 lbs

(68 kgs)

15-21. SPARE TIRE CARRIER AND DAVIT REPLACEMENT.

a. Removal.

The exhaust pipe and muffler can become very hot during vehicle operation. Be careful not

to touch these parts with bare hands, or allow body to come in contact with pipe or muffler.

Exhaust system parts can become hot enough to cause serious burns.

(1) Remove nut (1), screw (2) and pulley (3) from hoist arm extension (4).

(2) Remove lock pin (5) from retaining pin (6).

(3) Remove lock pin (5) from chain (7).
TM 9-2320-364-20-5

 15-61

Support hoist extension before

removing retaining pin or injury

to personnel may occur.

(4) Remove retaining pin (6) and hoist arm

extension (4) from hoist arm (8).

(5) Remove lock pin (9) and retaining pin (10)

from hoist arm (8).

(6) Remove lock pin (9) from chain (11).

(7) Remove locknut (12), washer (13),

screw (14), washer (15) and pulley (16) from

hoist arm extension (8). Discard locknut.

(8) Remove lock pin (17), retaining pin (18) and

hoist arm extension (8) from tire carrier

assembly (19).

(9) Remove lock pin (17) from chain (20).

(10) Remove nut (21), washer (22), screw (23),

washer (24) and pulley (25) from tire carrier

assembly (19).
TM 9-2320-364-20-5

15-62 

15-21. SPARE TIRE CARRIER AND DAVIT REPLACEMENT (CONT).

(11) Remove two nuts (26), screws (27) and

work lamp holder (28) from tire carrier

assembly (19).

(12) Remove two cotter pins (29), retaining

pins (30) and yokes (31) from frame (32)

and tire carrier (19). Discard cotter pins.

(13) Remove two yokes (31) and nuts (33) 

from rod (34).

31

29

32

30

33

34 33

31

19
TM 9-2320-364-20-5

 15-63

(14) Remove two cotter pins (35), retaining

pins (36) and yokes (37) from frame (32)

and tire carrier (19). Discard cotter pins.

(15) Remove two yokes (37) and nuts (38) 

from rod (39).

(16) Remove locknut (40), hook eye (41) and

washer (42) from fender assembly (43).

Discard locknut.

(17) Remove screw (44), washer (45) and anchor

strap (46) from tire carrier assembly (19).

(18) Remove two locknuts (47), one plate (48),

two screws (49) and tie down bracket (50)

from fender assembly (43). Discard

locknuts.
TM 9-2320-364-20-5

15-64 

15-21. SPARE TIRE CARRIER AND DAVIT REPLACEMENT (CONT).

• Do not touch hot exhaust system with bare hands; injury to personnel will result. If

necessary, use insulated pads and gloves.

• Tire carrier weighs 145 lbs (66 kg). Attach suitable lifting device prior to removal to

prevent possible injury to personnel.

(19) Attach lifting device to tire carrier assembly (19).

NOTE

• Note size and position of screws during removal.

• Hydraulic drain hose bracket may or may not be present in Step (20).

(20) With the aid of an assistant, remove three locknuts (51), screws (52) and hydraulic drain hose bracket (53)

from tire carrier (19) and fender assembly (43). Discard locknuts.

(21) With the aid of an assistant, remove two locknuts (54) and screw (55) from tire carrier (19) and fender

assembly (43). Discard locknuts.

(22) With the aid of an assistant, remove four locknuts (56) and screws (57) from tire carrier (19) and fender

assembly (43). Discard locknuts.

(23) With the aid of an assistant, guide tire carrier (19) away from fender assembly (43).
TM 9-2320-364-20-5

 15-65

b. Installation.

Tire carrier weighs 145 lbs (66 kg). Attach suitable lifting device prior to installation to

prevent possible injury to personnel.

(1) Attach lifting device to tire carrier assembly (19).

(2) With the aid of an assistant, install tire carrier assembly (19) onto fender assembly (43).

(3) With the aid of an assistant, install four screws (57) and locknuts (56) in tire carrier (19) and fender

assembly (43).

(4) With the aid of an assistant, install two screws (55) and locknuts (54) from tire carrier (19) and fender

assembly (43).

NOTE

Hydraulic drain hose bracket may or may not be present in Step (5).

(5) Install tire carrier (19) on fender assembly (43) with three screws (52), hydraulic drain hose bracket (53)

and locknuts (51).

(6) Install tie down bracket (50) on fender

assembly (43) with two screws (49),

plate (48) and two locknuts (47).
TM 9-2320-364-20-5

15-66 

15-21. SPARE TIRE CARRIER AND DAVIT REPLACEMENT (CONT).

(7) Install anchor strap (46) on tire carrier

assembly (19) with washer (45) and

screw (44).

(8) Install washer (42), hook eye (41) and

locknut (40) on fender assembly (43).

NOTE

Yoke assembly is adjusted

properly when there is equal

amount of threads in each yoke

and yokes line up with mounting

holes in frame and tire carrier.

(9) Position two nuts (38) and yokes (37) on

rod (39).

(10) Install yokes (37) on frame (32) and tire

carrier (19) with retaining pins (36) and

cotter pins (35).

(11) Tighten nuts (38) against yokes (37).
TM 9-2320-364-20-5

 15-67

(12) Position two nuts (33) and yokes (31) 

on rod (34).

NOTE

Yoke assembly is adjusted

properly when there is equal

amount of threads in each yoke

and yokes line up with mounting

holes in frame and tire carrier.

(13) Install yokes (31) on frame (32) and tire

carrier (19) with retaining pins (30) and

cotter pins (29).

(14) Tighten nuts (33) against yokes (31).

(15) Install work lamp holder (28) on tire carrier

assembly (19) with two screws (27) and

locknuts (26).

(16) Install pulley (25) on tire carrier

assembly (19) with washer (24), screw (23),

washer (22) and locknut (21). Tighten

locknut until five screw threads are

showing.

31

29

32

30

33

34 33

31

19
TM 9-2320-364-20-5

15-68 

15-21. SPARE TIRE CARRIER AND DAVIT REPLACEMENT (CONT).

(17) Install cotter pin (17) on chain (20).

(18) Install hoist arm (8) on tire carrier

assembly (19) with retaining pin (18) and

cotter pin (17).

(19) Apply grease to two washers (13) and (15)

and install one washer on each side of 

pulley (16).

(20) Install pulley (16) on hoist arm (8) with

washer (15), screw (14), washer (13) and

locknut (12). Tighten locknut until three

screw threads are showing.

(21) Install cotter pin (9) on chain (11).

(22) Install retaining pin (10) on hoist arm (8)

with cotter pin (9).

(23) Install cotter pin (5) on chain (7).

(24) Install hoist arm extension (4) on hoist

arm (9) with retaining pin (6) and cotter

pin (5).

(25) Install pulley (3) on hoist arm extension (4)

with screw (2) and locknut (1).

c. Follow-On Maintenance:

• Install spare tire carrier wire rope, (Para 15-23).

• Install right-side noise panel, (Para 17-26).

• Install right-side work lamp, (Para 7-55).

• Install spare tire, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 15-69

Materials/Parts

Locknut (3) (Item 133, Appendix F)

Locknut (3) (Item 140, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Spare tire carrier wire rope removed,

(Para 15-23)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

15-22. SPARE TIRE CARRIER WINCH REPLACEMENT.

a. Removal.

(1) Remove three locknuts (1), screws (2) and winch (3) from winch mounting bracket (4). Discard locknuts.
TM 9-2320-364-20-5

15-70 

15-22. SPARE TIRE CARRIER WINCH REPLACEMENT (CONT).

(2) Remove two locknuts (5), screws (6),

locknut (7), screw (8) and winch mounting

bracket (4) from fender assembly (9).

Discard locknuts.

b. Installation.

(1) Install winch mounting bracket (4) on fender

assembly (9) with two screws (6),

locknuts (5), locknut (7) and screw (8).

(2) Install winch (3) on winch mounting

bracket (4) with three screws (2) and

locknuts (1).

c. Follow-On Maintenance:

• Install spare tire carrier wire rope, (Para 15-23).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 15-71

Materials/Parts

Gloves, Heavy Duty (Item 33, Appendix C)

Grease (Item 42, Appendix C)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

15-23. SPARE TIRE CARRIER WIRE ROPE REPLACEMENT.

a. Removal.

• Wire rope can become frayed or contain broken wires. Wear heavy leather-palmed work

gloves when handling wire rope. Frayed or broken wires can cause injury to personnel.

• Never let moving wire rope slide through hands, even when wearing gloves. A broken wire

could cut through glove and can cause injury to personnel.

(1) Remove nut (1), bracket (2), screw (3) and wire rope (4) from winch (5).
TM 9-2320-364-20-5

15-72 

15-23. SPARE TIRE CARRIER WIRE ROPE REPLACEMENT (CONT).

NOTE

Discard wire rope, if removing

for repair.

(2) Remove wire rope (4) from hoist

assembly (6).

(3) Remove hose (7) from wire rope (4).

b. Installation.

(1) Apply grease to end of wire rope (4).

(2) Install hose (7) on wire rope (4).
TM 9-2320-364-20-5

 15-73

• Wire rope can become 

frayed or contain broken 

wires. Wear heavy leatherpalmed work gloves when

handling wire rope. Frayed 

or broken wires can cause 

injury to personnel.

• Never let moving wire rope

slide through hands, even 

when wearing gloves. A

broken wire could cut 

through glove and can cause

injury to personnel.

(3) Install wire rope (4) on hoist assembly (6).

(4) Install wire rope (4) on winch (5) with

screw (3), bracket (2) and nut (1).

(5) With the aid of an assistant, wind rope (4) 

on winch (5).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

15-74 

Materials/Parts

Locknut (4) (Item 117, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

15-24. AUXILIARY FUEL TANK TREAD PLATFORM ASSEMBLY REPLACEMENT.

a. Removal.

(1) Remove four screws (1), washers (2), locknuts (3) and tread platform assembly (4) from fuel tank straps

(5). Discard locknuts.

(2) Remove quick edge molding (6) from tread platform assembly (4).

b. Installation.

(1) Install quick edge molding (6) on tread platform assembly (4).

(2) Install tread platform assembly (4), four screws (1), washers (2) and locknuts (3) on fuel tank strips (5).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

3

5

4

6

2

1
TM 9-2320-364-20-5

 16-1

CHAPTER 16

SPRINGS AND SHOCKS MAINTENANCE

Para Contents Page

16-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

16-2 Shock Absorber and Bushing Replacement 16-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

16-3 Shock Absorber Mounts Replacement 16-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

16-1. INTRODUCTION.

This chapter contains maintenance instructions for removing, replacing and installing suspension components as

authorized by the Maintenance Allocation Chart (MAC) at the Unit Maintenance level.
TM 9-2320-364-20-5

16-2 

Materials/Parts

Bushing (4) (Item 4, Appendix F)

Locknut (2) (Item 142, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0 to 237 N.

m])

(Item 95, Appendix G)

16-2. SHOCK ABSORBER AND BUSHING REPLACEMENT.

a. Removal.

NOTE

All shock absorbers and bushings are removed the same way.

(1) Remove two locknuts (1) and washers (2) from studs (3) and (4). Discard locknuts.

(2) Remove shock absorber (5) and two washers (6) from studs (3) and (4).

(3) Remove four rubber bushings (7) from shock absorber (5). Discard bushings.
TM 9-2320-364-20-5

 16-3

b. Installation.

(1) Install washer (6) and rubber bushing (7) on

studs (3) and (4).

(2) Install shock absorber (5) and rubber

bushing (7) on studs (3) and (4).

(3) Install washer (2) and locknut (1) on

studs (3) and (4). Tighten nuts to 170 lb-ft

(230 N.

m).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

16-4 

Materials/Parts

Locknut (2) (Item 92, Appendix F)

Locknut (2) (Item 93 Appendix F)

This task covers:

a. Axle No. 1 Shock Absorber Mount Replacement e. Axle No. 4 Shock Absorber Mount Replacement

b. Axle No. 2 Shock Absorber Mount Replacement f. Follow-On Maintenance

c. Axle No. 3 Shock Absorber Mount Replacement

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Shock absorber removed, (Para 16-2)

Front access cover opened (Axle No. 1 only),

(TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket, Wrench Set 3/4 in. (Item 61, Appendix G)

Wrench, Combination 1-1/8 in.

(Item 79, Appendix G)

Wrench, Torque (0 to 300 lb-ft [0 to 407 N.

m])

(Item 96, Appendix G)

16-3. SHOCK ABSORBER MOUNTS REPLACEMENT.

NOTE

Right and left side mounts are

removed the same way.

a. Axle No. 1 Shock Absorber Mount 

Replacement.

(1) Removal.

(a) Remove two locknuts (1), screws (2)

and wire harness (3) from

crossmember (4). Discard locknuts.
TM 9-2320-364-20-5

 16-5

(b) Remove locknut (5) and stud (6) from

shock absorber bracket (7). Discard

locknut.

(c) With the aid of an assistant, remove

two locknuts (8) and screws (9) from

bracket (7). Discard locknuts.

NOTE

• Assistant must hold screws

through cab front access

panel.

• Position socket on locknut,

then position extension

through bottom frame hole

into socket.

(d) With the aid of an assistant, remove

locknut (10) and screw (11) from

bracket (7). Discard locknut.

(e) Repeat Step (d) for remaining

locknut (10) and screw (11). Discard

locknut.

(f) Remove shock absorber bracket (7)

from frame (12).

(2) Installation.

(a) Position shock absorber bracket (7) on

frame (12).

NOTE

Assistant must hold screws

through cab front access panel.

(b) With the aid of an assistant, position

two screws (11) and locknuts (10) in

bracket (7).

NOTE

Position socket on locknut, then position extension through bottom frame hole into socket.

(c) Tighten screw (11) and locknut (10) on bracket (7).

(d) Repeat Step (c) for remaining locknut (10) and screw (11).

(e) With the aid of an assistant, install two locknuts (8) and screws (9) in bracket (7).

(f) With the aid of an assistant, install stud (6) on shock absorber bracket (7) with locknut (5).

Tighten locknut (5) to 200 lb-ft (271 N.

m).
TM 9-2320-364-20-5

16-6 

16-3. SHOCK ABSORBER MOUNTS REPLACEMENT (CONT).

(g) Install wire harness (3) on

crossmember (4) with two screws (2)

and locknuts (1).

b. Axle No. 2 Shock Absorber Mount 

Replacement.

(1) Removal.

(a) Remove stud (1) from shock absorber

bracket (2).

(b) Remove locknut (3) and screw (4) from

bracket (2). Discard locknut.

(c) Remove locknut (3), screw (6) and

shock absorber bracket (2) from frame

(7). Discard locknut.

(2) Installation.

(a) With the aid of an assistant, install

shock absorber bracket (2) on frame (7)

screw (4) and screw (6) and two

locknuts (3).

(b) Install stud (1) on shock absorber

bracket (2).
TM 9-2320-364-20-5

 16-7/(16-8 blank)

c. Axle No. 3 Shock Absorber Mount 

Replacement.

(1) Removal.

(a) Remove two locknuts (1) and

screws (2) from bracket (5). Discard

locknuts.

(b) With the aid of an assistant, remove

locknut (3), screw (4) and shock

absorber bracket (5) from frame (6).

Discard locknut.

(2) Installation.

(a) With the aid of an assistant, install

shock absorber bracket (5) on frame (6)

with two screws (2), screw (4), two

locknuts (1) and locknut (3).

d. Axle No. 4 Shock Absorber Mount 

Replacement.

(1) Removal.

(a) With the aid of an assistant, remove two

locknuts (1), screws (2) and shock absorber

bracket (3) from frame (4). Discard

locknuts.

(2) Installation.

(a) With the aid of an assistant, install

shock absorber bracket (3) on frame (4)

with two screws (2) and locknuts (1).

e. Follow-On Maintenance:

• Install shock absorber, (Para 16-2).

• Remove wheel chocks, (TM 9-2320-364-10).

• Close front access cover (Axle No. 1 only), 

(TM 9-2320-364-10).

END OF TASK

TM 9-2320-364-20-5

 17-1

CHAPTER 17

CAB AND BODY MAINTENANCE

Para Contents Page

17-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2

17-2 Cab Fender Edging Replacement 17-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-3 Defroster Plenum Replacement 17-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-4 Heater Compartment Access Panel Replacement 17-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-5 Heater Compartment Front Cover Replacement 17-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-6 Fire Extinguisher Mount Replacement 17-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-7 Cab Door Adjustment 17-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-8 Cab Door And Hinge Replacement 17-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-9 Cab Door Repair 17-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-10 Engine Panel And Cover Assembly Replacement 17-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-11 Engine Cover Rubber Replacement 17-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-12 Engine Cover Latch Replacement 17-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-13 Engine Cover Grab Handle Replacement 17-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-14 Radiator Grille Assembly Replacement 17-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-15 Right, Left And Rear Grille Skins Replacement 17-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-16 Air Cleaner Skirt Replacement 17-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-17 Cooling Skirt Replacement 17-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-18 Right Hand Baffle Replacement 17-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-19 Cab Insulation Replacement 17-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-20 Electronic Control Box (ECB) Side Panel Replacement 17-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-21 Electronic Control Box (ECB) Right Side Panel Replacement 17-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-22 Electronic Control Box (ECB) Cover Replacement 17-66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-23 Electronic Control Box (ECB) Replacement 17-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-24 Cab Engine Access Panel Replacement 17-75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-25 Roof Cover Plate Replacement 17-76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-26 Right Side Noise Panel Replacement 17-77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-27 Left Front Noise Panel Replacement 17-79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-28 Left Side Noise Panel Replacement 17-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-29 Rear Noise Panel Replacement 17-85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-30 Rear Noise Panel Rubber Replacement 17-86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-31 Peep Window Replacement 17-88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-32 Rubber Fender Edging Replacement 17-90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-33 Right Fender Front And Rear Skirt Replacement 17-91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-34 Left Fender Front And Rear Skirt Replacement 17-93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-35 Rear Fender And Fender Support Arm Replacement 17-95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-36 Left Front Mud Flap Replacement 17-98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-37 Right Front Mud Flap Replacement 17-99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-38 Center Mud Flap Replacement 17-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-39 Rear Splash Guard (Mud Flap)/Reflector/Spring Bar Replacement 17-101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-40 Cab Seat Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-106

17-41 Cab Seat Lock Alignment Procedure 17-112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-42 Cab Seat Support Replacement 17-114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-43 Cargo Net Replacement 17-115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
TM 9-2320-364-20-5

17-2 

Para Contents Page

17-44 Seat Belt Replacement 17-116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-45 Sunvisor Replacement 17-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-46 Window Guard Replacement 17-121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-47 Foot Rest Repair 17-122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-48 Cab Floor Drain Plug Replacement 17-125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-49 Heater Control Side Panel Grab Handle Replacement 17-126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-50 Glove Box Grab Handle Replacement 17-127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-51 Instrument Panel Grab Handle Replacement 17-128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-52 Side Cab Grab Handle Replacement 17-129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-53 Glove Box Replacement 17-130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-54 Stowage Box And Bracket Replacement 17-133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-55 Crane Stowage Box Repair 17-138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-56 First Aid Kit Bracket Replacement 17-141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-57 Rifle Stowage Brackets Replacement 17-142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-58 Ladder Support Repair 17-148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-59 Threaded Screw Insert Replacement 17-150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-60 Stowage Box/Engine Cover Latch Adjustment 17-152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17-1. INTRODUCTION.

This chapter contains maintenance instructions for removing, replacing, installing and adjusting components of the 

cab and body as authorized by the Maintenance Allocation Chart (MAC) at the Unit Maintenance level.
TM 9-2320-364-20-5

 17-3

Materials/Parts

Lockwasher (9) (Item 195, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-2. CAB FENDER EDGING REPLACEMENT.

a. Removal.

NOTE

Both cab fender edgings are removed the same way. Left side shown.

(1) Remove three screws (1), lockwashers (2) and flatwashers (3) from cab (4). Discard lockwashers.

(2) Remove six screws (1), lockwashers (2), plate (5) and cab fender edging (6) from cab (4). Discard

lockwashers.

b. Installation.

(1) Install cab fender edging (6) on cab (4) with plate (5), six lockwashers (2) and screws (1).

(2) Secure cab fender edging (6) on cab (4) with three screws (1), lockwashers (2) and flatwashers (3).

c. Follow-on Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-4 

Materials/Parts

Adhesive (Item 7, Appendix C)

Lockwasher (Item 195, Appendix F)

Screw, Self-Tapping (6) (Item 315, Appendix F)

This task covers:

a. Removal c. Installation

b. Cleaning/Inspection d. Follow-on Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Instrument panel removed, (Para 7-13) (left

defroster plenum only)

Glove box door opened, (TM 9-2320-364-10)

(right defroster plenum only)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-3. DEFROSTER PLENUM REPLACEMENT.

a. Removal.

NOTE

• Perform Steps (1) through (3) for right defroster plenum only.

• Do not remove divider panel.

(1) Remove nut (1), lockwasher (2), screw (3) and bracket (4) from dash (5) and divider panel (6). Discard

lockwasher.

(2) Remove screw (7) from dash (5) and divider panel (6).

(3) Lay divider panel (6) down inside glove box (8).
TM 9-2320-364-20-5

 17-5

(4) Remove eight screws (9) and heater

compartment access panel (10) from heater

compartment (11).

(5) Remove six self-tapping screws (12) from dash (5) and two defroster plenums (13). Discard self-tapping

screws.

NOTE

It may be necessary to pry defroster plenums away from dash.

(6) Remove two defroster plenums (13) from dash (5).

b. Cleaning/Inspection.

(1) Clean sealant from mating surfaces of dash and defroster plenums.

(2) Inspect defroster plenums for cracks, dents or plugged vents.

(3) Replace all damaged parts.
TM 9-2320-364-20-5

17-6 

17-3. DEFROSTER PLENUM REPLACEMENT (CONT).

c. Installation.

NOTE

Install one defroster plenum at a time.

(1) Apply a bead of sealant to mating surface of defroster plenum (13).

(2) Position defroster plenum (13) on dash (5).

(3) Install six self-tapping screws (12) in dash (5) and defroster plenum (13).

(4) Install heater compartment access panel (10)

on heater compartment (11) using eight

screws (9).
TM 9-2320-364-20-5

 17-7

NOTE

Steps (5) through (7) apply to

right defroster plenum only.

(5) Position divider panel (6) in glove box (8)

using screw (7).

(6) Install bracket (4) and divider panel (6) on

dash (5) using screw (3), lockwasher (2) and

nut (1).

(7) Tighten screw (7) on dash (5) and divider

panel (6).

d. Follow-on Maintenance.

• Install instrument panel, (Para 7-13) (left defroster plenum only).

• Close glove box door, (TM 9-2320-364-10) (right defroster plenum only).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-8 

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-4. HEATER COMPARTMENT ACCESS PANEL REPLACEMENT.

a. Removal.

(1) Remove eight screws (1) and heater

compartment access panel (2) from heater

compartment (3).

(2) Remove four screws (4), spring clips (5) and

louvers (6) from heater compartment access

panel (2).

b. Installation.

(1) Install four louvers (6) on heater

compartment access panel (2) with spring

clips (5) and screws (4).

(2) Install heater compartment access panel (2)

on heater compartment (3) with eight screws

(1).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

3

2 1

4

5

6
TM 9-2320-364-20-5

 17-9

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Heater compartment access panel

removed, (Para 17-4)

Heater control panel removed, (Para 19-17)

Electronic Control Box (ECB) cover removed,

(Para 17-22)

Rectifier removed, (Para 7-19)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-5. HEATER COMPARTMENT FRONT COVER REPLACEMENT.

a. Removal. Remove four screws (1) and cover

(2) from heater compartment (3).

b. Installation. Install cover (2) and four

screws (1) on heater compartment (3).

c. Follow-On Maintenance:

• Install rectifier, (Para 7-19).

• Install Electronic Control Box (ECB) cover, (Para 17-22).

• Install heater control panel, (Para 19-17).

• Install heater compartment access panel, (Para 17-4).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-10 

Materials/Parts

Screw (4) (Item 299, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Fire extinguisher removed, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-6. FIRE EXTINGUISHER MOUNT REPLACEMENT.

a. Removal. Remove four screws (1) and fire extinguisher mount (2) from cab engine access panel (3). Discard

screws.

b. Installation. Install fire extinguisher mount (2) on cab engine access panel (3) with four screws (1).

c. Follow-On Maintenance:

• Install fire extinguisher, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-11

Materials/Parts

Pin, Cotter (2) (Item 271, Appendix F)

This task covers:

a. Adjustment b. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-7. CAB DOOR ADJUSTMENT.

a. Adjustment.

NOTE

Ensure window is in the upward position.

(1) Remove four screws (1) and inspection cover (2) from inner skin assembly (3).

NOTE

Use care when removing the

spring. Spring may fall between

inner skin and door.

(2) Remove spring (4) from rotary lock arm (5)

and door frame (6).

(3) Remove two cotters pins (7) and pins (8)

from clevis (9) and clevis (10). Discard

cotter pins.

(4) Remove outer link rod (11) and cable

assembly (12) from rotary lock arm (5).

(5) Position rotary lock (13) in closed position.

(6) Loosen jam nut (14) on outer link rod (11).
TM 9-2320-364-20-5

17-12 

17-7. CAB DOOR ADJUSTMENT (CONT).

 NOTE

Light upward pressure must be maintained on both outer link rod and cable assembly fitting

for proper alignment.

(7) While pulling up on outer link rod (11), 

adjust clevis (10) by turning clockwise or

counterclockwise until clevis aligns with hole

in rotary lock arm (5).

(8) Install outer link rod (11) in rotary lock

arm (5) with pin (8) and cotter pin (7), and

tighten jam nut (14).

(9) Loosen jam nut (14) on cable assembly (12).

(10) While pulling up on cable assembly (12),

adjust clevis (9) by turning clockwise or

counterclockwise until clevis aligns with

hole in rotary lock arm (5).

(11) Install clevis (9) with pin (8) and cotter

pin (7) on rotary lock arm (5).

NOTE

Use care when installing spring.

Spring may fall between inner

skin and door.

(12) Install spring (4) on door frame (6) and

rotary lock arm (5).

(13) Tighten jam nut (14) on cable

assembly (12).

(14) Unlatch door rotary lock (13).

(15) Shut door and check rotary lock (13)

operations.

(16) Install inspection cover (2) with four

screws (1) on inner skin assembly (3).

b. Follow-On Maintenance:

• Lubricate dovetail and door rotary lock,

(TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
LIFTING DEVICE

TM 9-2320-364-20-5

 17-13

Materials/Parts

Sealant, Metal (Item 69, Appendix C)

Sealing Compound (Item 73, Appendix C)

Locknut (Item 99, Appendix F)

Lockwasher (2) (Item 195, Appendix F)

Screw, Self-tapping (3) (Item 299, Appendix F)

Screw, Self-tapping (2) (Item 305, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Mirror bracket removed, (Para 19-3)

Amber reflector removed, (Para 19-2)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Lifting Device, Minimum Capacity 100 lbs

(45 kg)

Bit Set, Screwdriver (Item 6, Appendix G)

17-8. CAB DOOR AND HINGE REPLACEMENT.

Materials/Parts - Continued

Nut Strip (Item 336, Appendix F)

a. Removal.

Cab door weighs 100 lbs (45 kg). Support with suitable lifting device to avoid injury to

personnel.

NOTE

Procedure is identical for both doors. Left door is shown.

(1) Open door assembly (1) and roll window down.

(2) Attach lifting device to door assembly (1).
TM 9-2320-364-20-5

17-14 

17-8. CAB DOOR AND HINGE REPLACEMENT (CONT).

(3) Remove two self tapping screws (2), spacer (3) and door strap (4) from cab assembly (5).

(4) Remove two screws (6), lockwashers (7) and door strap (4) from door assembly (1). Discard lockwashers.

Doors must be removed with care to prevent damage to cab assembly.

(5) With the aid of an assistant, remove nine screws (8) and door assembly (1) from cab assembly (5).

(6) Remove lifting device from door assembly (1).

(7) Remove nine screws (8) and hinge (9) from

door assembly (1).
TM 9-2320-364-20-5

 17-15

(8) Remove three self-tapping screws (10) and

door seal bracket (11) from cab assembly (5).

Discard screws.

(9) Remove door seal (12) from cab

assembly (5).

NOTE

• Nut strip and locknut are

removed through cut out on

back side of door frame in

cab.

• Note position of nut strip

prior to removal.

• Nut strip can fall into door

jam during removal.

(10) Remove two screws (13), nut strip (14) and

dovetail guide (15) from cab assembly (5).

Discard nut strip.

(11) Remove locknut (16), washer (17) and

striker pin (18) from cab assembly (5).

Discard locknut.
TM 9-2320-364-20-5

17-16 

17-8. CAB DOOR AND HINGE REPLACEMENT (CONT).

b. Installation.

NOTE

• Procedure is identical for

both doors. Left door is

shown.

• Nut strip can fall into door

jam during installation.

• Locknut and nut strip are

installed through cut out on

backs side of door frame in

cab.

(1) Install dovetail guide (15) and nut strip (14)

on cab assembly (5) with two screws (13).

(2) Install striker pin (18) and washer (17) on

cab assembly (5) with locknut (16).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(3) Apply sealing compound in corners of cab

door opening.

(4) Install door seal (12) on cab assembly (5).

(5) Install door seal bracket (11) on cab

assembly (5) with three self-tapping

screws (10).
LIFTING DEVICE

TM 9-2320-364-20-5

 17-17

(6) Position hinge (9) on door assembly (1) with

nine screws (8).

Cab door weighs 100 lbs (45 kg). Support with suitable lifting device to avoid injury to personnel.

Doors must be installed with care to prevent damage to cab assembly.

(7) Attach lifting device to door assembly (1).
TM 9-2320-364-20-5

17-18 

17-8. CAB DOOR AND HINGE REPLACEMENT (CONT).

Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and

are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use in

well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash

immediately with soap and water.

(8) Apply sealing compound to hinge holes on cab assembly (5).

(9) With the aid of an assistant, line up door assembly (1) with cab assembly (5) and install nine screws (8) in

cab assembly (5).

(10) Remove lifting device and lifting strap from door assembly (1).

(11) Shut door assembly (1) and check operation. If door does not shut properly, repeats Steps (7) and (9),

realign door assembly (1) and tighten 18 screws (8).

(12) Install door strap (4) and lockwashers (7) on door assembly (1) with two screws (6).

(13) Install spacer (3) and door strap (4) on cab assembly (5) with two screws (2).

(14) Apply metal sealant to all seams and joints of door assembly (1).

(15) Roll up window on door assembly (1).

c. Follow-On Maintenance:

• Adjust door, (Para 17-7).

• Install mirror bracket, (Para 19-3).

• Install amber reflector, (Para 19-2).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-19

Materials/Parts

Adhesive, HM (Item 11, Appendix C)

Adhesive (Item 15, Appendix C)

Primer (Item 64, Appendix C)

Sealing Compound (Item 77, Appendix C)

Solution, Soap (Item 86, Appendix C)

Channel (Item 9, Appendix F)

Channel, Rubber (Item 11, Appendix F)

This task covers:

a. Disassembly c. Assembly

b. Cleaning/Inspection d. Follow-On Maintenance

INITIAL SETUP

Materials/Parts - Continued

Locknut (9) (Item 139, Appendix F)

Lockwasher (2) (Right Side) 

(Item 171, Appendix F)

Pin, Cotter (4) (Item 271, Appendix F)

Screw, Machine (6) (Item 295, Appendix F)

Screw, Self-Locking (Item 298, Appendix F)

Seal, Preformed (Item 331, Appendix F)

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Rifle stowage bracket removed

(right side cab door), (Para 17-57)

Door removed, (Para 17-8)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Torque (0 to 60 N.

m)

(Item 98, Appendix G)

17-9. CAB DOOR REPAIR.

a. Disassembly.

NOTE

Left cab door and right cab door

are identical unless noted. Left

cab door is shown for disassembly.

(1) Remove four screws (1) and cover (2) from

door assembly (3).

(2) Remove four screws (4) and handle (5) from

door assembly (3).
TM 9-2320-364-20-5

17-20 

17-9. CAB DOOR REPAIR (CONT).

(3) Remove screw (6), window crank (7), cover

(8) and spring (9) from door assembly (3).

NOTE

Use care when removing spring.

Spring may fall out between 

inner skin and door.

(4) Remove spring (10) from rotary lock

arm (11) and door assembly (3).

(5) Loosen jam nut (12) on outer link rod (13)

and cable assembly (14).

(6) Remove two cotter pins (15) and pins (16)

from clevis (17). Discard cotter pins.

(7) Remove cable assembly (14) from rotary

lock arm (11).

(8) Remove outer link rod (13) from rotary lock

arm (11).
TM 9-2320-364-20-5

 17-21

(9) Remove four screws (18) and dovetail

assembly (19) from door assembly (3).

NOTE

Rotary lock must be in closed

position to permit removal.

(10) Remove three screws (20), rotary lock (21)

and two spacer plates (22) from door

assembly (3).

(11) Remove 14 screws (23) from door

assembly (3).

(12) Remove six screws (24) and inner skin

assembly (25) from door assembly (3).

NOTE

Perform Step (13) if rifle mount

plate is present on right side cab

door and damaged.

(13) Remove two screws (26), lockwashers (27),

washers (28) and rifle mount plate (29) from

inner skin assembly (25). Discard

lockwashers. 25

26 27 28

29
TM 9-2320-364-20-5

17-22 

17-9. CAB DOOR REPAIR (CONT).

(14) Remove six machine screws (30) and

window regulator (31) from door

assembly (3).

(15) Remove channel (32) from door

assembly (3). Discard channel.

(16) Remove two screws (33), locknuts (34) and

window guide (35) from door assembly (3).

Discard locknuts.

(17) Remove cotter pin (36), retainer pin (37) 

and threaded rod (38) from lever (39).

Discard cotter pin.

(18) Remove locknut (40), handle retaining

bracket (41) and outside handle (42) from

door assembly (3). Discard locknut.
TM 9-2320-364-20-5

 17-23

(19) Remove locknut (43) and inside handle (44) from door assembly (3). Discard locknut.

(20) Remove cotter pin (45), retaining pin (46) and cable (47) from door assembly (3). Discard cotter pin.

(21) Loosen nut (48) and remove clevis (17) and

jam nut (48) from cable (49).

(22) Remove cable (49) from pulley

assemblies (50).

NOTE

Pulley assemblies are removed 

by turning counterclockwise 

from brackets.

(23) Remove three nuts (51) and pulley

assemblies (50) from bracket (52).

Do not let window fall. Broken

glass may cause serious injury to

personnel.

(24) Remove window (53) from door

assembly (3).
TM 9-2320-364-20-5

17-24 

17-9. CAB DOOR REPAIR (CONT).

(25) Remove three channels (54) from door

assembly (3).

(26) Remove weather stripping (55) from door

assembly (3).

(27) Remove lock strip (56), window (57) and

rubber channel (58) from door assembly

(3). Discard lock strip and rubber channel.

b. Cleaning/Inspection.

(1) Clean excess grease from cable and rollers.

(2) Replace any worn, defective, or cracked parts.

(3) Clean excess adhesive from door and window guide using primer.
TM 9-2320-364-20-5

 17-25

c. Assembly.

Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and

are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use 

in a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing,

wash immediately with soap and water.

NOTE

Procedure is identical for both

cab doors unless noted. Left side

cab door is shown for assembly.

(1) Apply adhesive to weather stripping (55).

(2) Install weather stripping (55) on door

assembly (3).

(3) Apply soap solution to rubber channel (58)

and on door assembly (3).

(4) Install rubber channel (58) in door

assembly (3).

(5) Apply primer to ends of rubber channel (58).

(6) Apply adhesive to ends of rubber

channel (58).

Do not let window fall. Broken

glass may cause serious injury.

(7) Install window (57) in rubber channel (58).

(8) Apply soap solution to rubber channel (58)

and lock strip (56).

(9) Install lock strip (56) in rubber channel (58).

(10) Apply primer to ends of lock strip (56).

(11) Apply adhesive to ends of lock strip (56).
TM 9-2320-364-20-5

17-26 

17-9. CAB DOOR REPAIR (CONT).

NOTE

Inside channel needs to be cut

1.25 inches (3.18 cm) longer than

window channel.

(12) Cut three channels (54) to fit window

channels in door assembly (3).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and water.

(13) Apply adhesive to window channels in door

assembly (3).

NOTE

Inside channel will over hang

1.25 inches below window

channel.

(14) Install channels (54) in window channels on

door assembly (3).

(15) Install window (53) in door assembly (3).

(16) Install three pulley assemblies (50) and

three nuts (51) on bracket (52).

(17) Install cable (49) on pulley assemblies (50).

(18) Position jam nut (48) and clevis (17) on

cable (49).
TM 9-2320-364-20-5

 17-27

(19) Install outside handle (42), handle retaining

bracket (41) and locknut (40) in door

assembly (3).

(20) Install threaded rod (38), retaining pin (37)

and cotter pin (36) on lever (39).

(21) Install cable (47), retaining pin (46) and

cotter pin (45) on inside handle (44).

(22) Install inside handle (44) in door

assembly (3) with locknut (43).
TM 9-2320-364-20-5

17-28 

17-9. CAB DOOR REPAIR (CONT).

(23) Install window guide (35) on door

assembly (3) with two screws (33) and

locknuts (34).

(24) Cut channel (32) to fit window guide (35).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(25) Apply adhesive to window guide (35).

(26) Install channel (32) in window guide (35).

(27) Install window regulator (31) on door

assembly (3) with two screws (30).
TM 9-2320-364-20-5

 17-29

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and water.

(28) Apply sealing compound on threads of

three screws (20).

(29) Position two spacer plates (22) and rotary

lock (21) in door assembly (3) with three

screws (20).

(30) Tighten three screws (20) to 130 lb-in

(15 N.

m).

(31) Install dovetail assembly (19) on door

assembly (3) with four screws (18).

(32) Tighten four screws (18) to 36 lb-in

(4 N.

m).

(33) Install outer link rod (13) on rotary lock

arm (11) with pin (16) and cotter pin (15).

(34) Install cable assembly (14) on rotary lock

arm (11) with pin (16) and cotter pin (15).

(35) Install spring (10) on rotary lock arm (11)

and door assembly (3).
TM 9-2320-364-20-5

17-30 

17-9. CAB DOOR REPAIR (CONT).

NOTE

Perform Step (36) if rifle mount

plate was removed.

(36) Install rifle mount plate (29) on inner skin

assembly (25) with two washers (28),

lockwashers (27) and screws (26). Tighten

screws to 100 lb-in (11 N.

m).

(37) Install inner skin assembly (25) on door

assembly (3) with six screws (24) and 14

screws (23).

NOTE

Window crank should point down

when window is down.

(38) Install spring (9), cover (8) and window

crank (7) on door assembly (3) with

screw (6).

25

26 27 28

29
TM 9-2320-364-20-5

 17-31

(39) Install cover (2) on door assembly (3) with

four screws (1).

(40) Install handle (5) on door assembly (3) with

four screws (4).

d. Follow-On Maintenance:

• Install cab door, (Para 17-8).

• Install rifle stowage bracket (right side cab door) (Para 17-57).

• Adjust cab door, (Para 17-7).

• Remove wheel chocks, (TM 9-2320-364-20).

END OF TASK
TM 9-2320-364-20-5

17-32 

Materials/Parts

Locknut (10) (Item 106, Appendix F)

Locknut (4) (Item 110, Appendix F)

Locknut (2) (Item 140, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Engine cover rubber removed, (Para 17-11)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-10. ENGINE PANEL AND COVER ASSEMBLY REPLACEMENT.

a. Removal.

(1) Turn engine cover latch handle (1) and unlock engine cover (2).

(2) Open engine cover (2) on engine panel (3).

(3) Remove ten locknuts (4) and screws (5) from engine cover (2). Discard locknuts.

(4) Remove engine cover (2) from engine panel (3).

(5) Remove four screws (6), locknuts (7) and engine cover latch (1) from engine cover (2). Discard locknuts.

(6) Remove two locknuts (8), screws (9) and grab handle (10) from engine panel (2). Discard locknuts.
TM 9-2320-364-20-5

 17-33

(7) Remove 11 screws (11), washers (12) and

engine panel (3) from frame (13).

b. Installation.

(1) Install engine panel (3) with 11 screws (11)

and washers (12) on frame (13).

(2) Install grab handle (10), two screws (9) and

locknuts (8) on engine panel (3).

(3) Install engine cover latch (1), four screws (6)

and locknuts (7) on engine cover (2).

(4) Install engine cover (2) on engine panel (3)

with ten screws (5) and locknuts (4).

(5) Close engine cover (2) on radiator

shroud (3).

(6) Turn engine cover latch handle (1) and lock

engine cover (2).

c. Follow-On Maintenance:

• Install engine cover rubber, (Para 17-11).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-34 

Materials/Parts

Locknut (9) (Item 106, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-on Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-11. ENGINE COVER RUBBER REPLACEMENT.

a. Removal.

(1) Turn handle (1) and unlock engine cover (2).

(2) Open engine cover (2) on engine panel (3).

(3) Remove nine locknuts (4), screws (5), three retaining strips (6), (7) and (8) and rubber (9) from engine

cover (2). Discard locknuts.

b. Installation.

(1) Install rubber (9), three retaining strips (6), (7) and (8), nine screws (5) and locknuts (4) on engine

cover (2).

(2) Close engine cover (2).

c. Follow-on Maintenance.

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-35

Materials/Parts

Locknut (4) (Item 110, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Engine Cover Opened,

(TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-12. ENGINE COVER LATCH REPLACEMENT.

a. Removal. Remove four locknuts (1), screws (2) and engine cover latch (3) from engine cover (4). 

Discard locknuts.

b. Installation. Install engine cover latch (3) on engine cover (4) with four screws (2) and locknuts (1).

c. Follow-On Maintenance.

• Adjust engine cover latch, (Para 17-60).

• Close engine cover, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

2

4

3

1
TM 9-2320-364-20-5

17-36 

Materials/Parts

Locknut (2) (Item 140, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-13. ENGINE COVER GRAB HANDLE REPLACEMENT.

a. Removal. Remove two locknuts (1), screws (2) and grab handle (3) from engine cover (4). Discard locknuts.

b. Installation. Install grab handle (3) on engine cover (4) with two screws (2) and locknuts (1).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-37

Materials/Parts

Locknut (4) (Item 91, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Radiator grille skins removed, (Para 17-15)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0 to 237 N.

m])

(Item 95, Appendix G)

17-14. RADIATOR GRILLE ASSEMBLY REPLACEMENT.

a. Removal.

(1) With the aid of an assistant, remove four locknuts (1), eye hooks (2) and grille assembly (3) from frame (4).

Discard locknuts.

(2) Remove seal edging (5) from both front and rear edge of grille assembly (3).

b. Installation.

(1) Install seal edging (5) on both front and rear edge of grille assembly (3).

(2) With the aid of an assistant, install grille assembly (3) on frame (4) with four eye hooks (2) and

locknuts (1). Tighten locknuts to 55 lb-ft (74 N.

m).

c. Follow-On Maintenance:

• Install radiator grille skins, (Para 17-15).

• Remove wheel chocks, (TM 9-2320-264-10).

END OF TASK
TM 9-2320-364-20-5

17-38 

Materials/Parts

Locknut (Item 98, Appendix F)

Locknut (9) (Item 106, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Spare tire removed, (TM 9-2320-364-10)

Right side noise panel removed, (Para 17-26)

Ether start disconnected, (Para 4-18)

Engine panel and cover assembly

removed, (Para 17-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-15. RIGHT, LEFT AND REAR GRILLE SKINS REPLACEMENT.

a. Removal.

(1) Remove five screws (1), washers (2) and angle (3) from right grille skin panel (4).

(2) Remove locknut (5) and screw (6) from right

grille skin panel (4) and bracket (7).
TM 9-2320-364-20-5

 17-39

(3) Remove two screws (8), washers (9), right

grille skin panel (4) and muffler shield (10)

from frame (11).

(4) Remove three locknuts (12), rubber (13),

retaining strip (14) and screw (15) from

muffler shield (10). Discard locknuts.

(5) Remove clamp (16) and aspirator hose (17)

from exhaust pipe (18).

(6) Remove two screws (19) and washers (20)

from rear grille skin (21).

(7) Remove five screws (22), washers (23) 

and rear grille skin (21) from frame (11).

(8) Remove two locknuts (24), four 

washers (25), two screws (26) and cooling

skirt (27) from rear grille 

skin (21). Discard locknuts.

(9) Remove two locknuts (28), four 

washers (29) and two screws (30) 

from left side grille skin panel (31) and

cooling skirt (32). Discard locknuts.

(10) Remove two screws (33) and washers 

(34) from left grille skin panel (31).

(11) Remove five screws (35), washers (36) 

and left side grille skin panel (31) from

frame (11).

(12) Remove two locknuts (37), screws (38) 

and deflector (39) from left grille skin panel

(31). Discard locknuts.

35

36 38

31 37

33

34

39

30 29

32

28

22

27

25

24

23

21

20

19

16 1 18

1

26

17
TM 9-2320-364-20-5

17-40 

17-15. RIGHT, LEFT AND REAR GRILLE SKINS REPLACEMENT (CONT).

b. Installation.

(1) Install deflector (39) on left grille skin

panel (31) with two screws (38) and 

locknuts (37).

(2) Install left grille skin panel (31) on frame

(11) with five washers (36) and screws (35).

(3) Install two washers (34) and screws (33) 

on left skin panel (31).

(4) Install two screws (30), four washers (29)

and two locknuts (28) on left 

side grille skin panel (31) and cooling 

skirt (32).

(5) Install cooling skirt (27) with two

screws (26), four washers (25) and 

two locknuts (24) on rear grille skin (21).

(6) Position rear grille skin (21) on frame 

(11) with five washers (23) and screws (22).

(7) Position two washers (20) and screws (19) 

on rear grille skin (21).

(8) Install hose clamp (16) and hose (17) on

exhaust pipe (18).

(9) Install rubber (13) and retaining strip (14)

with three screws (15) and locknuts (12) on

muffler shield (10).

35

36 38

31 37

33

34

39

30 29

32

28

22

27

25

24

23

21

20

19

16 1 18

1

26

17
TM 9-2320-364-20-5

 17-41

(10) Install right grille skin (4) on frame (11)

with two washers (9) and screws (8).

(11) Tighten five screws (22) and two screws

(19) on rear grille skin (21).

(12) Install screw (6) and locknut (5) on right

grille skin (4) and bracket (7).

(13) Install angle (3) on right grille skin (4) with

five washers (2) and screws (1).

c. Follow-On Maintenance:

• Install engine panel and cover, (Para 17-10).

• Connect ether start, (Para 4-18).

• Install right side noise panel, (Para 17-26).

• Install spare tire, (TM 9-2320-264-10).

• Remove wheel chocks, (TM 9-2320-264-10).

END OF TASK
TM 9-2320-364-20-5

17-42 

Materials/Parts

Locknut (6) (Item 133, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Air cleaner assembly removed, (Para 4-4)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-16. AIR CLEANER SKIRT REPLACEMENT.

a. Removal. Remove six locknuts (1), washers (2), skirt (3), three brackets (4) and six screws (5) from left 

side power module frame (6). Discard locknuts.

b. Installation. Install six screws (5), three brackets (4), skirt (3), six washers (2) and locknuts (1) on left 

side power module frame (6).

c. Follow-On Maintenance:

• Install air cleaner assembly, (Para 4-4).

• Wheel chocks removed, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-43

Materials/Parts

Locknut (4) (Item 106, Appendix F)

Lockwasher (4) (Item 180, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Left side noise panel removed, (Para 17-28)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-17. COOLING SKIRT REPLACEMENT.

a. Removal.

NOTE

Only remove center screw on engine side of LHS control box cover.

(1) Remove four screws (1), lockwashers (2) and cover (3) from mount (4). Discard lockwashers.
TM 9-2320-364-20-5

17-44 

17-17. COOLING SKIRT REPLACEMENT (CONT).

(2) Remove two locknuts (5), washers (6) and screws (7) from cooling skirt (8) and bracket (9). Discard

locknuts.

(3) Remove two locknuts (10), four washers (11), cooling skirt (8) and two screws (12) from left side grille

skin panel (13). Discard locknuts.

b. Installation.

(1) Install cooling skirt (8) with two screws (12), four washers (11) and two locknuts (10) on left side grille

skin panel (13).

(2) Install cooling skirt (8) with two screws (7), washers (6) and locknuts (5) on bracket (9).

(3) Install cover (3) on mount (4) with four

lockwashers (2) and screws (1).

c. Follow-On Maintenance:

• Install left side noise panel, (Para 17-28).

• Wheel chocks removed, (TM 9-2320-364-10).

END OF TASK

12

6

7

11

10

9

5

8

13
TM 9-2320-364-20-5

 17-45

Materials/Parts

Locknut (7) (Item 93, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Main hydraulic reservoir removed, (Para 20-12)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-18. RIGHT HAND BAFFLE REPLACEMENT.

a. Removal.

(1) Remove four locknuts (1) washers (2), screws (3) and two brackets (4) from right hand baffle (5).

(2) Remove two locknuts (1), screws (6), bracket (4) and right hand baffle (5) from right side power module

frame (7).

(3) Remove locknut (1), washer (2), plate (8) and screw (3) from right hand baffle (5).

b. Installation.

(1) Position plate (8) on right hand baffle (5) with screw (3), washer (2) and locknut (1).

(2) Position right hand baffle (5) on right side power module frame (7) with bracket (4), two screws (6),

washers (2) and locknuts (1).

(3) Position two brackets (4) on right side power module frame (7) and right hand baffle (5) with four

screws (3), washers (2) and locknuts (1).

(4) Tighten seven locknuts (1).

c. Follow-on Maintenance:

• Install main hydraulic reservoir, (Para 20-12).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-46 

Materials/Parts

Adhesive (Item 3, Appendix C)

Adhesive, Insulation (Item 12, Appendix C)

Insulation, Cab (Item 52, Appendix C)

Tape, Adhesive (Item 90, Appendix C)

This task covers:

a. Removal c. Locations of Insulation Panels e. Follow-On Maintenance

b. Installation d. Specifications of Insulation Panels

INITIAL SETUP

Equipment Condition - Continued

Beacon bracket removed, (Para 19-9)

Cab dome light removed, (Para 7-49)

Seats removed, (Para 17-40)

Cargo net removed, (Para 17-43)

Seat belts removed, (Para 17-44)

Gas particulate filter unit (If equipped),

(Para 24-2)

Decontamination bracket removed

Equipment Condition (If equipped), (Para 24-3)

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-19. CAB INSULATION REPLACEMENT.

a. Removal.

NOTE

Perform Step (1) if insulation is

held in place with retaining strips.

If not, start with Step (2).

(1) Remove eight screws (1) and four retaining

strips (2) from insulation (3) and cab

shell (4).

NOTE

Insulation for floor is under cab

shell.

(2) Remove insulation (3) from cab shell (4).

b. Installation.

NOTE

• Ensure that insulation panels

meet specifications of

drawings in Step d.

• Ensure that insulation panel

fits section of cab shell to be

covered.

• If insulation panel has

finished and rolled edges,

perform Step (1). If not, start

with Step (2).

(1) Apply double-sided adhesive tape on back of

insulation panel along finished, rolled edge.
TM 9-2320-364-20-5

 17-47

Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and

are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use in

well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash

immediately with soap and water.

• Use insulation adhesive on all panels that are installed inside cab. Use adhesive on panels that

are installed under floor. Using wrong adhesive will cause premature failure.

• Ensure that cab shell is free of old adhesive, insulation, dirt, and grease. Dirty surface will

cause premature failure.

NOTE

• Ensure that adhesive is applied to side of insulation panel that contacts cab shell.

• Ensure that floor insulation is installed under cab shell.

(2) Coat insulation panel (3) with adhesive.

(3) Position insulation panel (3) on cab shell (4).

(4) Press insulation panel (3) uniformly over

entire surface.

NOTE

If original insulation panel had

retaining strip, perform Step (5).

If not, go to e. Follow-On

Maintenance.

(5) Install four retaining strips (2) on insulation

panel (3) and secure with eight screws (1)

into cab shell (4).
TM 9-2320-364-20-5

17-48 

17-19. CAB INSULATION REPLACEMENT (CONT).

c. Location of Insulation Panels.
TM 9-2320-364-20-5

 17-49

d. Specifications of Insulation Panels.
TM 9-2320-364-20-5

17-50 

17-19. CAB INSULATION REPLACEMENT (CONT).
TM 9-2320-364-20-5

 17-51
TM 9-2320-364-20-5

17-52 

17-19. CAB INSULATION REPLACEMENT (CONT).
TM 9-2320-364-20-5

 17-53
TM 9-2320-364-20-5

17-54 

17-19. CAB INSULATION REPLACEMENT (CONT).
TM 9-2320-364-20-5

 17-55
TM 9-2320-364-20-5

17-56 

17-19. CAB INSULATION REPLACEMENT (CONT).

e. Follow-On Maintenance:

• Install decontamination bracket, (Para 24-3).

• Install gas particulate filter unit, (Para 24-2).

• Install seat belts, (Para 17-44).

• Install cargo net, (Para 17-43).

• Install seats, (Para 17-40).

• Install cab dome light, (Para 7-49).

• Install beacon bracket, (Para 19-9).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-57

Materials/Parts

Locknut (Item 94, Appendix F)

Lockwasher (Item 195, Appendix F)

Screw (10) (Item 294, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Drill (Item 17, Appendix G)

Drill Set, Twist (Item 19, Appendix G)

Tool Kit, Blind Rivet (Item 72, Appendix G)

17-20. ELECTRONIC CONTROL BOX (ECB) SIDE PANEL REPLACEMENT.

a. Removal.

(1) Remove six screws (1) from side panel (2) and pull side panel away from control panel (3).
TM 9-2320-364-20-5

17-58 

17-20. ELECTRONIC CONTROL BOX (ECB) SIDE PANEL REPLACEMENT (CONT).

NOTE

Perform Steps (2) and (3) if

equipped with LHS Controller

Protection Kit.

(2) Disconnect wires 1755 (4) and 1755A (5)

from fuse holder (6).

(3) Disconnect relay connector (7) from

relay (8).

NOTE

Connectors are removed by

gently prying up on tab and

pulling connectors apart.

(4) Disconnect MC93 connector (9).

(5) Disconnect MC94 connector (10).

(6) Remove screw (11), lockwasher (12) and

wire 1052 (13) from panel light (14).

Discard lockwasher.

(7) Disconnect S22 connector (15) from transfer

case lockout rocker switch (16).

(8) Disconnect L35 connector (17) from pilot

light housing (18).

(9) Remove screw (19), nut (20) and

rectifier (21) from side panel (2).

NOTE

Perform Step (10) only if truck is

equipped with chemical alarm 

kit. If truck is not equipped with

chemical alarm kit, go to 

Step (11).

(10) Disconnect C4 connector (22) and S20

connector (23) from chemical alarm rocker

switch (24).

14 13 12 7

8

9

11

6

5

4

10
TM 9-2320-364-20-5

 17-59

NOTE

Perform Step (11) only if truck is

equipped with gas particulate kit.

If truck is not equipped with gas

particulate kit, go to Step (12).

(11) Disconnect C3 connector (25) and S19

connector (26) from gas particulate filter

rocker switch (27).

(12) Disconnect C2 connector (28) and S10

connector (29) from winch in/out rocker

switch (30).

(13) Disconnect C1 connector (31) and S4

connector (32) from winch/crane rocker

switch (33).

(14) Disconnect 439 wire (34) and wire 1052

(35) from engine stop rocker switch (36).

(15) Remove side panel (2) from truck and

position on clean work surface.

(16) Loosen screw (37) and remove hydraulic

selector switch handle (38) from hydraulic

selector switch (39).

(17) Remove hydraulic selector switch face

plate (40) from hydraulic selector

switch (39).

(18) Remove four screws (41) and hydraulic

selector switch mounting plate (42) from

side panel (2).
TM 9-2320-364-20-5

17-60 

17-20. ELECTRONIC CONTROL BOX (ECB) SIDE PANEL REPLACEMENT (CONT).

NOTE

Perform Steps (19) through (21)

if equipped with LHS Controller

Protection Kit.

(19) Remove screw (43), locknut (44) and relay

(8) from side panel (2). Discard locknut.

(20) Remove two nuts (45), fuse holders (6) and

seals (46) from front of side panel (2).

(21) Remove two covers (47) and fuses (48)

from fuse holders (6).

(22) Remove nut (49) and washer (50) from 

panel light (14).

(23) Remove panel light (14) from side panel

(2).

NOTE

There are seven rocker switches

and one pilot light housing. All

are removed the same way.

(24) Push tab (51) on back of rocker switches

(36), (33), (30), (27), (24), (18) and (16)

and remove each switch from side panel (2).

(25) Drill out rivets (52) from four data

plates (53), (54), (55) and (56) and

remove each data plate from side panel (2).

Discard rivets.

NOTE

• Perform Step (26) if

equipped with LHS

Controller Protection Kit.

• Perform Step (26) if data

plate is damaged.

(26) Remove fuse data plate (57) from side panel (2).

b. Installation.

NOTE

• Perform Step (1) if equipped

with LHS Controller

Protection Kit.

• Perform Step (1) if data plate

was removed.

(1) Position fuse data plate (57) on side panel (2).

24

49

36

46

27 30

44

33

45

45

18

14

47

48

8

2

16 43

46

6

6

47

6

6

48

51

50
TM 9-2320-364-20-5

 17-61

NOTE

There are four data plates secured

with rivets. All four data plates

are installed the same way.

(2) Position and install four data

plates (53), (54), (55) and (56) on

side panel (2) with rivets (52).

NOTE

There are seven rocker switches

and one pilot light housing. All

are installed the same way.

(3) Install rocker switches (16), (18), (36),

(33), (30), (27) and (24) on side 

panel (2) until tabs (51) on rocker 

switches are secure.

(4) Install panel light (14) on side panel (2).

(5) Install washer (50) and nut (49) on panel

light (14).

NOTE

Perform Steps (6) through (8) if

equipped with LHS Controller

Protection Kit.

(6) Position two fuses (48) in fuse holders

(6) and install covers (47).

(7) Install two seals (46) and fuse holders

(6) on side panel (2) with two nuts (45).

(8) Install relay (8) on side panel (2) with

screw (43) and locknut (44).

(9) Install hydraulic selector switch (39),

hydraulic selector switch mounting

plate (42) and four screws (41) on side

panel (2).

(10) Install hydraulic selector switch face

plate (40) on hydraulic selector switch (39).

(11) Install hydraulic selector switch handle (38)

on hydraulic selector switch (39) and tighten

screw (37).

24

49

36

46

27 30

44

33

45

45

18

14

47

48

8

2

16 43

46

6

6

47

6

6

48

51

50
TM 9-2320-364-20-5

17-62 

17-20. ELECTRONIC CONTROL BOX (ECB) SIDE PANEL REPLACEMENT (CONT).

(12) Position side panel (2) in truck.

(13) Connect wire 439 (34) and wire 1052 (35)

on engine stop rocker switch (36).

(14) Connect C1 connector (31) and S4 

connector (32) on winch/crane rocker

switch (33).

(15) Connect C2 connector (28) and S10

connector (29) on winch in/out rocker

switch (30).

NOTE

Perform Step (16) only if truck is

equipped with gas particulate 

kit. If truck is not equipped with

gas particulate kit, go to

Step (17).

(16) Connect C3 connector (25) and S19

connector (26) to gas particulate rocker

switch (27).

NOTE

Perform Step (17) only if truck is

equipped with chemical alarm 

kit. If truck is not equipped with

chemical alarm kit, go to

Step (18).

(17) Connect C4 connector (22) and S20

connector (23) to chemical alarm rocker

switch (24).
TM 9-2320-364-20-5

 17-63

(18) Install rectifier (21), screw (19) and nut (20)

on side panel (2).

(19) Connect L35 connector (17) on pilot light

housing (18).

(20) Connect S22 connector (15) on transfer

case lockout rocker switch (16).

(21) Install wire 1052 (13), lockwasher (12) and

screw (11) on panel light (14).

(22) Connect MC94 connector (10).

(23) Connect MC93 connector (9).

NOTE

Perform Steps (24) and (25) if

equipped with LHS Controller

Protection Kit.

(24) Connect relay connector (7) to relay (8).

(25) Connect wires 1755A (5) and 1755 (4) to

fuse holder (6).

(26) Position side panel (2) against control

panel (3) and install six screws (1) in side

panel (2).

c. Follow-On Maintenance:

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

14 13 12 7

8

9

11

6

5

4

10
TM 9-2320-364-20-5

17-64 

Materials/Parts

Adhesive, Insulation (Item 12, Appendix C)

Insulation (Item 80, Appendix F)

Seal (Item 328, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-21. ELECTRONIC CONTROL BOX (ECB) RIGHT SIDE PANEL REPLACEMENT.

a. Removal.

(1) Remove 10 screws (1) and electronic control box panel (2) from cab (3).

(2) Remove and discard insulation (4) and

seal (5) from electronic control box

panel (2).
TM 9-2320-364-20-5

 17-65

b. Installation.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(1) Apply insulation adhesive to insulation (4).

(2) Install insulation (4) on electronic control

box panel (2).

(3) Apply insulation adhesive to edges of

insulation (4).

(4) Apply insulation adhesive to seal (5).

(5) Install seal (5) on electronic control box

panel (2).

(6) Install electronic control box panel (2) with

10 screws (1) on cab (3).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-66 

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-22. ELECTRONIC CONTROL BOX (ECB) COVER REPLACEMENT.

a. Removal.

(1) Remove 15 screws (1) from left and right

covers (2).

(2) Remove left and right covers (2) from

electronic control box (3).

NOTE

Do not tighten screws until all 

15 are installed.

b. Installation. Install left and right covers (2) with 

15 screws (1) on electronic control box (3).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-67

Materials/Parts

Cable Ties (Item 26, Appendix C)

Tags, Identification (Item 88, Appendix C)

Locknut (Item 140, Appendix F)

Lockwasher (2) (Item 194, Appendix F)

Lockwasher (17) (Item 204, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Electronic Control Box (ECB) cover

removed, (Para 17-22)

Electronic Control Box (ECB) side panel

removed, (Para 17-20)

Machine gun platform removed, (Para 22-5)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/8 Drive (Item 62, Appendix G)

Wrench, Torque, 3/8 in. Drive (0 to 60 N.

m)

(Item 98, Appendix G)

17-23. ELECTRONIC CONTROL BOX (ECB) REPLACEMENT.

a. Removal.

NOTE

• Tag and mark all wires and connections prior to removal.

• Remove cable ties as required.

(1) Loosen screws (1) and disconnect MC9 connector (2) and MC10 connector (3) from ATEC (4).

(2) Remove locknut (5), wire 222, wire 234 (6) and cable (7) from stud (8). Discard locknut.

(3) Disconnect connectors MC50 (9), MC51 (10) and MC36 (11).
TM 9-2320-364-20-5

17-68 

17-23. ELECTRONIC CONTROL BOX (ECB) REPLACEMENT (CONT).

(4) Remove two screws (12), locknuts (13) and

ferrites (14) from wire harness (15) and (16).

(5) Remove four screws (17), two plates (18)

and rubber grommets (19) from electronic

control box (20).

(6) Push connectors (2), (3), (9), (10) and (11)

through electronic control box (20).

NOTE

Wire 1075B will remain on relay.

(7) Remove nut (21), lockwasher (22) and wires 1075 (23), 1958 (24) and 1075B (25) from relay R25 (26).

Discard lockwasher.

(8) Remove nut (27), lockwasher (28) and wire 1430 (29) from relay R28 (30). Discard lockwasher.

(9) Remove nut (31), lockwasher (32) and wire 1281 (33) from relay R26 (34). Discard lockwasher.
TM 9-2320-364-20-5

 17-69

(10) Disconnect wire 225 (35) from circuit breaker CB11 (36).

NOTE

Wire 1867 will remain with circuit breaker.

(11) Remove screw (37), lockwasher (38) and wires 1867 (39) and 1866 (40) from circuit breaker CB12 (41).

Discard lockwasher.

(12) Remove screw (42), lockwasher (43) and wire 1079 (44) from circuit breaker CB5 (45). Discard

lockwasher.

(13) Remove screw (46), lockwasher (47) and wire 241 (48) from circuit breaker CB22 (49). Discard

lockwasher.

(14) Remove screw (50), lockwasher (51) and wire 240 (52) from circuit breaker CB23 (53). Discard

lockwasher.

(15) Disconnect wires 241 (54) and 240 (55) from circuit breakers CB22 (49) and CB23 (53).

(16) Push wires 1075 (23), 1430 (29), 1079 (44), 1281 (33), 1866 (40), 241 (54), 240 (55), 240 (52) and 241

(48) through electronic control box (20).

(17) Loosen screws (56) and disconnect

connectors MC1 (57) and MC2 (58).

(18) Disconnect connectors MC106 (59) and

MC116 (60).
TM 9-2320-364-20-5

17-70 

17-23. ELECTRONIC CONTROL BOX (ECB) REPLACEMENT (CONT).

(19) Loosen screw (61) and disconnect MC25 (62).

(20) Disconnect connectors MC11 (63) and MC40 (64).

(21) Remove locknut (65), lockwasher (66) and wire 1435 (67) from stud (68).

(22) Loosen screw (69) and disconnect 

connector MC44 (70).

(23) Remove nut (71), lockwasher (72),

flatwasher (73) and wire 1435 (74) from

stud (75).

(24) Remove 14 screws (76) from electronic

control box (20).

(25) Remove electronic control box (20) from

truck.

b. Installation.

(1) Install electronic control box (20) with 14

screws (76).

(2) Install wire 1435 (73) to stud (75) with

flatwasher (73), lockwasher (72) and

nut (71).

(3) Connect MC44 connector (70) and tighten

screw (69).
TM 9-2320-364-20-5

 17-71

(4) Install wire 1435 (67) to stud (68) with lockwasher (66) and locknut (65).

(5) Connect MC11 connector (63) and MC40 connector (64).

(6) Connect MC25 connector (62) and tighten screw (61).

(7) Connect MC106 connector (59).

(8) Connect MC116 connector (60).

(9) Connect MC2 connector (58) and tighten

screw (56).

(10) Connect MC1 connector (57) and tighten

screw (56).
TM 9-2320-364-20-5

17-72 

17-23. ELECTRONIC CONTROL BOX (ECB) REPLACEMENT (CONT).

(11) Push wires 1075 (23), 1430 (29), 1079 (44), 1281 (33), 1866 (40), 241 (54), 240 (55), 240 (52) and 241

(48) through electronic control box (20).

(12) Connect wire 241 (55) and wire 240 (54) to circuit breakers CB23 (53) and CB22 (49).

(13) Install wire 240 (52) to circuit breaker CB23 (53) with screw (50) and lockwasher (51).

(14) Install wire 241 (48) to circuit breaker CB22 (49) with screw (46) and lockwasher (47).

(15) Install wire 1079 (44) to circuit breaker CB5 (45) with screw (42) and lockwasher (43).

(16) Install wires 1867 (39) and 1866 (40) to circuit breaker CB12 (41) with screw (37) and lockwasher (38).

(17) Connect wire 225 (35) to circuit breaker CB11 (36).
TM 9-2320-364-20-5

 17-73

(18) Position wire 1281 (33) on relay R26 (34) with lockwasher (32) and nut (31). Tighten nut to 30 to 35 lb-in

(3 to 4 N.

m).

(19) Position wire 1430 (29) on relay R28 (30) with lockwasher (28) and nut (27). Tighten nut to 30 to 35 lb-in

(3 to 4 N.

m).

(20) Position wires 1075 (23), wire 1958 (24) and 1075B (25) on relay R25 (26) with lockwasher (23) and nut

(22). Tighten nut to 30 to 35 lb-in (3 to 4 N.

m).

(21) Push connectors MC9 (2), MC10 (3),

MC50 (9), MC51 (10), and MC36 (11)

through electronic control box (20).

(22) Install two plates (18) to electronic control

box (20) with four screws (17) and two

rubber grommets (19).

(23) Install wire harnesses (15) and (16) with

ferrites (14), screws (12) and locknuts (13).
TM 9-2320-364-20-5

17-74 

17-23. ELECTRONIC CONTROL BOX (ECB) REPLACEMENT (CONT).

(24) Connect MC36 connector (11).

(25) Connect MC51 connector (10).

(26) Connect MC50 connector (9).

(27) Install cable (7), wire 222 and wire 

234 (6) to stud (8) with locknut (5).

(28) Connect connectors MC9 (2) and 

MC10 (3) on ATEC (4) with screws (1).

c. Follow-On Maintenance:

• Install machine gun platform, (Para 22-5).

• Install Electronic Control Box (ECB) side panel, (Para 17-20).

• Install Electronic Control Box (ECB) cover, (Para 17-22).

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-75

Materials/Parts

Lockwasher (22) (Item 195, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Fire extinguisher removed,

(TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-24. CAB ENGINE ACCESS PANEL REPLACEMENT.

a. Removal.

(1) Remove 22 screws (1), lockwashers (2) and washers (3) from cab engine access panel (4). Discard

lockwashers.

(2) Remove cab engine access panel (4) from cab (5).

b. Installation.

(1) Position cab engine access panel (4) in cab (5).

(2) Install 22 washers (3), lockwashers (2) and screws (1) in cab engine access panel (4).

c. Follow-On Maintenance:

• Install fire extinguisher, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-76 

Materials/Parts

Gasket (Item 68, Appendix F)

Washer, Sealing (34) (Item 353, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Torque, 3/8 in. Drive

(Item 98, Appendix G)

17-25. ROOF COVER PLATE REPLACEMENT.

a. Removal.

(1) Remove 34 screws (1) and sealing washers (2) from roof cover plate (3). Discard sealing washers.

(2) Remove cover plate (3) and gasket strips (4) from roof (5). Discard gasket strips.

b. Installation.

(1) Cut gasket strips (4) to lengths of two pieces each at 34 in. (86 cm) and 24 in. (61 cm) and one piece at 

14 in. (35 cm).

(2) Position gasket (4) on roof cover plate (3).

(3) Position cover plate (3) on roof (5).

(4) Punch 34 holes in gasket strips (4) using cover plate (3) as a template.

(5) Install 34 sealing washers (2) and screws (1) in cover plate (3). Tighten screws 204 lb-in (23 N.

m).

c. Follow-On Maintenance:

• Remove wheels chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-77

Materials/Parts

Lockwasher (6) (Item 171, Appendix F)

Pin, Cotter (3) (Item 273, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Spare tire removed, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-26. RIGHT SIDE NOISE PANEL REPLACEMENT.

a. Removal.

(1) Remove and discard cotter pin (1) from clevis yoke (2).

(2) Remove clevis pin (3) from clevis yoke (2).

(3) Slide clevis yoke (2) downward through right side noise panel (4).

(4) Remove and discard two cotter pins (5) from clevis yoke (6).

(5) Remove two clevis pins (7) from clevis yoke (6).

(6) Remove clevis yoke (6) from two clevis studs (8).

(7) Remove six screws (9), lockwashers (10) and washers (11) from right side noise panel (4). Discard

lockwashers.

(8) Pull rubber flap (12) out from under fan shroud (13).
TM 9-2320-364-20-5

17-78 

17-26. RIGHT SIDE NOISE PANEL REPLACEMENT (CONT).

NOTE

Push in on radiator skin and

remove noise panel.

(9) Remove right side noise panel (4) from

truck.

b. Installation.

NOTE

Push in on radiator skin to install

noise panel.

(1) Position right side noise panel (4) on truck.

(2) Push rubber flap (12) under fan shroud (13).

(3) Install six washers (11), lockwashers (10)

and screws (9) in right side noise panel (4).

(4) Position clevis yoke (6) on two clevis

studs (8).

(5) Install two clevis pins (7) in clevis yoke (6).

(6) Install two cotter pins (5) in clevis yoke (6).

(7) Pull clevis yoke (2) through right side noise

panel (4).

(8) Install clevis pin (3) in clevis yoke (2).

(9) Install cotter pin (1) in clevis pin (2).

c. Follow-On Maintenance:

• Install spare tire, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-79

Materials/Parts

Lockwasher (4) (Item 171, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Arctic battery box removed

(if equipped), (Para 22-6)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-27. LEFT FRONT NOISE PANEL REPLACEMENT.

a. Removal.

(1) Remove four screws (1), lockwashers (2), washers (3) and rubber (4) from left front noise panel (5).

Discard lockwashers.

(2) Remove rubber (4) and left front noise panel (5) from truck (6).

b. Installation.

(1) Position rubber (4) and left front noise panel (5) on truck (6).

(2) Install four washers (3), lockwashers (2) and screws (1) in left front noise panel (5) and rubber (4).

c. Follow-On Maintenance:

• Install arctic battery box (if equipped), (Para 22-6).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-80 

Materials/Parts

Adhesive, Insulation (Item 10, Appendix C)

Sealant, Rubber (Item 70, Appendix C)

Insulation (Item 78, Appendix F)

Insulation (Item 79, Appendix F)

Locknut (6) (Item 91, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Materials/Parts - Continued

Locknut (Item 106, Appendix F)

Locknut (Item 109, Appendix F)

Locknut (9) (Item 133, Appendix F)

Lockwasher (8) (Item 171, Appendix F)

Seal (Item 321, Appendix F)

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-28. LEFT SIDE NOISE PANEL REPLACEMENT.

a. Removal.

(1) Remove eight screws (1), lockwashers (2) and washers (3) from left side noise panel (4). Discard

lockwashers.

Ensure left side noise panel does not contact either the start aid assembly or electrical cables

upon removal or damage to equipment may result.

(2) Remove left side noise panel (4) from truck (5).
TM 9-2320-364-20-5

 17-81

(3) Remove nine locknuts (6), three washers (7),

nine screws (8), strip (9) and seal (10) from

left side noise panel (4). Discard locknuts.

(4) Remove and discard insulation (11) from 

left side noise panel (4).

(5) Remove locknut (12), screw (13) and

retaining strap (14) from left side noise 

panel (4). Discard locknut.

(6) Remove locknut (15), screw (16) and

latch (17) from left side noise panel (4).

Discard locknut.

(7) Remove two locknuts (18), screws (19) and

hook seat (20) from door (21). Discard

locknuts.

(8) Remove four locknuts (22), screws (23),

spacer (24) and door (21) from left side

noise panel (4).

(9) Remove quickedge (25) from left side noise

panel (4).

(10) Remove and discard insulation (26) from

door (21).
TM 9-2320-364-20-5

17-82 

17-28. LEFT SIDE NOISE PANEL REPLACEMENT (CONT).

b. Installation.

Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and 

are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use 

in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, 

wash immediately with soap and water.

(1) Apply insulation adhesive on 

insulation (26).

(2) Install insulation (26) on door panel (21).

(3) Apply insulation sealant to edges of

insulation (26).

(4) Install quickedge (25) on left side noise

panel (4).

(5) Install door (21) and spacer (24) on left side

noise panel (4) with four screws (23) and

locknuts (22).

(6) Install hook seat (20), two screws (19) and

locknuts (18) in door (21).

(7) Install latch (17) in left side noise panel (4)

with screw (16) and locknut (15).

(8) Install retaining strap (14) in latch (17) with

screw (13) and locknut (12).
TM 9-2320-364-20-5

 17-83

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(9) Apply insulation adhesive on insulation (11).

(10) Install insulation (11) on left side noise

panel (4).

(11) Apply insulation sealant to edges of

insulation (11).

(12) Install seal (10), three washers (7), nine

screws (8), strip (9) and nine locknuts (6) in

left side noise panel (4).
TM 9-2320-364-20-5

17-84 

17-28. LEFT SIDE NOISE PANEL REPLACEMENT (CONT).

Ensure left side noise panel

remains free from contacting

either start aid assembly or

electrical cables upon removal or

damage to equipment may result.

(13) Position left side noise panel (4) on

truck (5).

(14) Install eight washers (3), lockwashers (2)

and screws (1) in left side noise panel (4).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-85

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-29. REAR NOISE PANEL REPLACEMENT.

a. Removal.

(1) Remove two pins (1) from rear noise

panel (2).

NOTE

Observe position of rear noise

panel and how it hooks into 

place for installation.

(2) Remove rear noise panel (2) from truck (3).

b. Installation.

(1) Install rear noise panel (2) on truck (3).

(2) Install two pins (1) in rear noise panel (2).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-86

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Materials/Parts - Continued

Locknut (8) (Item 106, Appendix F)

Pad, Rubber (Item 264, Appendix F)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-30. REAR NOISE PANEL RUBBER REPLACEMENT.

Materials/Parts

Adhesive (Item 3, Appendix C)

Adhesive, Insulation (Item 12, Appendix C)

Insulation (Item 77, Appendix F)

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Rear noise panel removed, (Para 17-29)

a. Removal.

(1) Remove eight locknuts (1), three retaining

strips (2) and (3), rear panel rubber (4) and

eight screws (5) from rear noise panel (6).

Discard locknuts.

NOTE

Perform Step (2) if insulation or

pads are damaged.

(2) Remove insulation (7) and rubber pads (8)

from rear noise panel (6).
TM 9-2320-364-20-5

 17-87

b. Installation.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

NOTE

• Perform Steps (1) through (4)

if insulation or rubber pads

were removed.

• Ensure that adhesive is

applied to side of insulation

that contacts rear panel.

(1) Coat insulation (7) with adhesive.

(2) Position insulation (7) on rear noise panel

(6).

(3) Press insulation (7) evenly over entire

surface.

(4) Coat one side of rubber pads (8) with

adhesive.

(5) Install rubber pads (8) on rear noise panel

(6).

(6) Install eight screws (5), rear panel 

rubber (4), three retaining strips (2) and (3)

and eight locknuts (1) on rear noise panel

(6).

c. Follow-On Maintenance:

• Install rear noise panel, (Para 17-29).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-88

Materials/Parts

Adhesive (Item 15, Appendix C)

Primer (Item 64, Appendix C)

Solution, Soap (Item 86, Appendix C)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Materials/Parts - Continued

Channel, Rubber (40 in.) (Item 10, Appendix F)

Lockwasher (2) (Item 171, Appendix F)

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-31. PEEP WINDOW REPLACEMENT.

a. Removal.

Always wear proper eye protection and protective clothing when handling glass. Failure to

comply may result in injury to personnel.

(1) Remove two screws (1), lockwashers (2) and bar (3) from skid plate (4). Discard lockwashers.

(2) Remove windshield seal locking strip (5) from peep window (6).

NOTE

Ensure to reach around cab to support peep window when pushing peep window out through

cab. Failure to comply may result in damage to parts.

(3) Push peep window (6) out from inside of cab (7).

NOTE

Perform Step (4) if rubber channel is damaged.

(4) Remove and discard rubber channel (8) from cab (7).
TM 9-2320-364-20-5

 17-89

b. Installation.

Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and 

are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use 

in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, 

wash immediately with soap and water.

NOTE

Perform Steps (1) and (2) if

rubber channel was removed.

(1) Apply primer to rubber channel ends (8).

(2) Apply adhesive to rubber channel ends (8)

and install rubber channel in cab (7).

(3) Apply soap solution to rubber channel (8).

(4) Install peep window (6) in rubber

channel (8).

NOTE

Ensure ends of rubber channel 

are not in same position as ends

of windshield seal locking strip 

or leakage may occur.

(5) Apply soap solution to rubber channel (8)

and install windshield seal locking strip (5)

over peep window (6) on rubber channel.

(6) Apply primer to ends of windshield seal

locking strip (5).

(7) Apply adhesive to ends of windshield seal

locking strip (5) and secure in place.

(8) Install bar (3) on skid plate (4) with two

lockwashers (2) and screws (1).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-90

Materials/Parts

Locknut (26) (Item 106, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-32. RUBBER FENDER EDGING REPLACEMENT.

a. Removal.

NOTE

Both rubber fender edgings are removed the same way, right side shown.

(1) Remove two locknuts (1), screws (2) and bracket (3) from right fender (4). Discard locknuts.

(2) With the aid of an assistant remove 24 locknuts (5), screws (6), two strips (7), and rubber fender edging (8)

from right fender (4). Discard locknuts.

b. Installation.

(1) With the aid of an assistant, position rubber fender edging (8) on right fender (4) with two strips (7) and 24

screws (6) and locknuts (5).

(2) Install bracket (3) on right fender (4) with two screws (2) and locknuts (1).

(3) Tighten 24 locknuts (5) on screws (6).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-91

Materials/Parts

Locknut (13) (Item 134, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-33. RIGHT FENDER FRONT AND REAR SKIRT REPLACEMENT.

a. Removal.

(1) Remove locknut (1), screw (2) and washer (3) from bracket (4). Discard locknut.

(2) Remove five locknuts (5), screws (6), washers (7) and right front fender skirt (8) from right fender (9).

Discard lockwashers.

(3) Remove seven locknuts (10), screws (11), washers (12) and right rear fender skirt (13) from right

fender (9). Discard locknuts.
TM 9-2320-364-20-5

17-92

17-33. RIGHT FENDER FRONT AND REAR SKIRT REPLACEMENT (CONT).

b. Installation.

(1) Install seven screws (11), washers (12) and

right rear fender skirt (13) on right fender (9)

with seven locknuts (10). Tighten screws

until rubber compresses.

(2) Install five screws (6), washers (7) and right

front fender skirt (8) on right fender (9) with

five locknuts (5). Tighten screws until

rubber compresses.

(3) Install screw (2) and washer (3) on

bracket (4) with locknut (1). Tighten screw

until rubber compresses.

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-93

Materials/Parts

Locknut (5) (Item 95, Appendix F)

Locknut (3) (Item 106, Appendix F)

Locknut (6) (Item 134, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-34. LEFT FENDER FRONT AND REAR SKIRT REPLACEMENT.

a. Removal.

(1) Remove three locknuts (1), screws (2), washers (3) and left rear fender skirt (4) from skirt brackets (5).

Discard locknuts.

(2) Remove six locknuts (6), screws (7), and washers (8) from left rear fender skirt (4) and left fender (9).

Discard locknuts.

(3) Remove five locknuts (10), screws (11), cushion clips (12) and washers (13) from left front fender skirt

(14) and left fender (9). Discard locknuts.
TM 9-2320-364-20-5

17-94

17-34. LEFT FENDER FRONT AND REAR SKIRT REPLACEMENT (CONT).

b. Installation.

(1) Install five screws (11), cushion clips (12),

washers (13) and left front fender skirt (14)

on left fender (9) with locknuts (10).

Tighten screws until rubber compresses.

(2) Install left rear fender skirt (4) on left 

fender (9) with six screws (7), washers (8)

and locknuts (6).

(3) Install left rear fender skirt (4) on three 

skirt brackets (5) with screws (2), washers

(3) and locknuts (1).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-95

Materials/Parts

Clip, Push (6) (Item 24, Appendix F)

Locknut (2) (Item 91, Appendix F)

Locknut (4) (Item 106, Appendix F)

Locknut (3) (Item 140, Appendix F)

Screw, Self-Tapping (Item 313, Appendix F)

This task covers:

a. Removal c. Installation d. Follow-On Maintenance

b. Cleaning/Inspection

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Center mud flap removed, (Para 17-38)

Rear fender side marker lamp

removed, (Para 7-48)

Rear fender reflector removed, (Para 19-2)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-35. REAR FENDER AND FENDER SUPPORT ARM REPLACEMENT.

a. Removal.

NOTE

Push clips are removed by first pulling out lock button, then removing clip.

(1) Remove six push clips (1) and marker lamp wiring harness (2) from fender support arm (3). Discard 

push clips.

(2) Remove self-tapping screw (4) from fender support arm (3). Discard self-tapping screw.

(3) Remove two locknuts (5) and screws (6) from fender support arm (3). Discard locknuts.

(4) Remove locknut (7), washer (8) and screw (9) from fender support arm (3) and fender brace (10). Discard

locknut.
TM 9-2320-364-20-5

17-96

17-35. REAR FENDER AND FENDER SUPPORT REPLACEMENT (CONT).

(5) Remove rear fender (11) from fender support

arm (3).

(6) Remove four locknuts (12), screws (13) and

two braces (14) from rear fender (11).

Discard locknuts.

(7) With the aid of an assistant, remove

locknut (15), screw (16) and brace (17) from

truck frame (18). Discard locknuts.

(8) With the aid of an assistant, remove

locknut (19), screw (20), spacer (21) and

fender support arm (3) from truck

frame (18). Discard locknut.

b. Cleaning/Inspection.

(1) Inspect rear fender, fender support arm and

fender brace for cracks and broken welds.

(2) Replace all damaged parts.

c. Installation.

(1) With the aid of an assistant, position fender

support arm (3), spacer (21), screw (20) and

locknut (19) on truck frame (18).

(2) With the aid of an assistant, install

brace (17), screw (16) and locknut (15) in

truck frame (18).

(3) With the aid of an assistant, tighten

locknut (19) on screw (20).
TM 9-2320-364-20-5

 17-97

(4) Install two braces (14) on rear fender (11)

using four screws (13) and locknuts (12).

(5) Position rear fender (11) on fender support

arm (3).

(6) Position screw (9), washer (8) and

locknut (7) in fender support arm (3) and

fender brace (10).

(7) Install two screws (6) and locknuts (5) in

fender support arm (3).

(8) Tighten locknut (7) on screw (9).

(9) Install self-tapping screw (4) in fender

support arm (3).

NOTE

Push clips are properly installed

when lock button is pushed in

after installation.

(10) Install marker lamp wiring harness (2) and

six push clips (1) on fender support arm (3).

d. Follow-On Maintenance:

• Install rear fender reflector, (Para 19-2).

• Install rear fender side marker lamp, (Para 7-48).

• Install center mud flap, (Para 17-38).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-98

Materials/Parts

Locknut (9) (Item 133, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-36. LEFT FRONT MUD FLAP REPLACEMENT.

a. Removal.

(1) Remove locknut (1), screw (2) and two

washers (3), from mud flap (4), rubber

flap (5) and mud flap (6). Discard locknut.

(2) Remove two locknuts (7), screws (8)

washers (9) and mud flap (4) from mud

flap (6). Discard locknuts.

(3) Remove three locknuts (10), washers (11),

screws (12) and rubber flap (5) from fender

assembly (13). Discard locknuts.

(4) Remove three locknuts (14), screws (15),

clamping plate (16) and mud flap (6) from

fender assembly (13). Discard locknuts.

b. Installation.

(1) Install mud flap (6) and clamp plate (16) on

fender assembly (13) with three screws (15)

and locknuts (14).

(2) Install rubber mud flap (5) with three

screws (12), washers (11) and locknuts (10)

on fender assembly (13).

(3) Install mud flap (4) with two washers (9),

screws (8) and locknuts (7) on rubber

flap (5).

(4) Install two washers (3), screw (2) and

locknut (1) on mud flap (4), rubber flap (5)

and mud flap (6).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-99

Materials/Parts

Locknut (3) (Item 133, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-37. RIGHT FRONT MUD FLAP REPLACEMENT.

a. Removal. Remove three locknuts (1), screws (2), 

retaining plate (3) and mud flap (4) from fender 

(5). Discard locknuts.

b. Installation. Install mud flap (4) on fender (5) 

with retaining plate (3), screws (2) and 

locknuts (1).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-100

Materials/Parts

Locknut (3) (Item 133, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-38. CENTER MUD FLAP REPLACEMENT.

NOTE

Procedures are identical for both

sides of truck. Left side shown.

a. Removal. Remove three locknuts (1), screws (2), 

clamping plate (3) and mud flap (4) from fender 

assembly (5). Discard locknuts.

b. Installation. Install mud flap (4) on fender 

assembly (5) with clamping plate (3), three 

screws (2) and locknuts (1).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-101

Materials/Parts

Locknut (4) (Item 91, Appendix F)

Locknut (2) (Item 93, Appendix F)

Locknut (6) (Item 106, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set 3/4 in. (Item 61, Appendix G)

17-39. REAR SPLASH GUARD (MUD FLAP)/REFLECTOR/ SPRING BAR 

 REPLACEMENT.

Materials/Parts - Continued

Locknut (Item 133, Appendix F)

Pin, Cotter (Item 276, Appendix F)

a. Removal.

NOTE

• Both right and left splash guard/reflector are removed the same way.

• Right side shown.

(1) Remove four locknuts (1), plate (2), four screws (3) and bracket (4) from spring bar (5). Discard 

locknuts.

(2) Remove two locknuts (6), screws (7), reflector housing (8), reflector (9) and gasket (10) from bracket (4).

Discard locknuts.
TM 9-2320-364-20-5

17-102

17-39. REAR SPLASH GUARD (MUD FLAP)/REFLECTOR/SPRING BAR 

REPLACEMENT (CONT).

(3) Remove locknut (11) and splash guard hook

(12) from clip (13). Discard locknut.

(4) Remove two locknuts (14), two screws (15),

three clips (13) and splash guard (16) from

spring bar (5). Discard locknuts.

(5) Remove two locknuts (17), screw (18) and

two splash guard strips (19) from splash

guard (16). Discard locknuts.

(6) Remove cotter pin (20) and spring bar (5)

from mounting bracket (21). Discard cotter

pin.

(7) Remove two locknuts (22), screws (23) and

mounting bracket (21) from splash guard

mounting bracket (24). Discard locknuts.
TM 9-2320-364-20-5

 17-103

(8) Remove two locknuts (25), screws (26) 

and lower composite light mounting 

bracket (27) from splash guard mounting

bracket (24). Discard locknuts.

NOTE

• Perform Step (9) if truck is

not equipped with CHU.

• Perform Step (10) if truck is

equipped with CHU.

(9) Remove two locknuts (28), screws (29) 

and splash guard mounting bracket (24)

from rear crossmember (30). Discard

locknuts.

(10) Remove two locknuts (31), screws (32),

spacer (33) and splash guard mounting

bracket (24) from rear crossmember (30).

Discard locknuts.

b. Installation.

NOTE

• Perform Step (1) if truck is

equipped with CHU.

• Perform Step (2) if truck is

not equipped with CHU.

(1) Install splash guard mounting bracket (24)

and spacer (33) with two locknuts (31) and

screws (32) to rear crossmember (30).

(2) Install splash guard mounting bracket 

(24) with two locknuts (28) and screws 

(29) to rear crossmember (30).

(3) Install composite light mounting

bracket (27) with two screws (26) and

locknuts (25) to splash guard mounting

bracket (24).

32

24

33

31

30
TM 9-2320-364-20-5

17-104

17-39. REAR SPLASH GUARD (MUD FLAP)/REFLECTOR/SPRING BAR 

REPLACEMENT (CONT).

(4) Install mounting bracket (21) with two

screws (23) and locknuts (22) on splash

guard mounting bracket (24).

(5) Install spring bar (5) with cotter pin (20) 

to mounting bracket (21).

(6) Install two splash guard strips (19) with two

screws (18) and locknuts (17) to splash

guard (16).

(7) Install splash guard (16), three clips (13),

two screws (15) and locknuts (14) to spring

bar (5).

(8) Install splash guard hook (12) with

locknut (11) to clip (13).
TM 9-2320-364-20-5

 17-105

(9) Install gasket (10), reflector (9), reflector

housing (8), two screws (7) and locknuts (6)

to bracket (4).

(10) Install bracket (4), four screws (3), plate (2)

and locknuts (1) to spring bar (5).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-106

Materials/Parts

Cloth, Cleaning (Item 31, Appendix C)

Solution, Soap (Item 86, Appendix C)

Locknut (4) (Item 128, Appendix F)

Locknut (2) (Item 132, Appendix F)

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

17-40. CAB SEAT REPAIR.

Materials/Parts - Continued

Lockwasher (3) (Item 170, Appendix F)

a. Removal

NOTE

Procedure is identical for both seats. Left seat is shown.

(1) Remove locknut (1), screw (2), washer (3), seat belt bracket (4) and tether bracket (5) from seat 

assembly (6). Discard locknut.
TM 9-2320-364-20-5

 17-107

NOTE

Bushing may fall from seat

assembly during removal.

(2) Remove locknut (7), screw (8), washers (9),

seat belt (10) and tether bracket (11) from

seat assembly (6). Discard locknut.

Seat assembly weighs 55 lbs 

(25 kg). Attach suitable lifting

device to prevent possible injury

to personnel.

(3) Remove four nuts (12) from studs (13) and

with the aid of an assistant, guide seat

assembly (6) away from seat support (14)

and cab assembly (15).
TM 9-2320-364-20-5

17-108

17-40. CAB SEAT REPAIR (CONT).

b. Disassembly.

(1) Remove nut (1), lockwasher (2) and screw (3) from shock absorber (4) and seat assembly (5). Discard

lockwasher.

(2) Remove nut (6), lockwasher (7), screw (8) and shock absorber (4) from seat assembly (5). Discard

lockwasher.

(3) Remove bushing (9) and spacer (10) from shock absorber (4).

(4) Remove two screws (11), clips (12) and seat cushion (13) from seat assembly (5).

(5) Remove five hooks (14) and seat cover (15) from seat assembly (5).
TM 9-2320-364-20-5

 17-109

(6) Remove spring (16) from seat assembly (5).

NOTE

Record position of torsion

springs prior to disassembly.

(7) Remove four locknuts (17), screws (18),

right torsion spring (19), left torsion spring

(20) and slide assembly (21) from seat

assembly (5). Discard locknuts.

(8) Loosen jam nut (22) on rod (23).

(9) Remove knob (24) from rod (23).

c. Cleaning/Inspection.

(1) Clean seat cover using soap solution.

(2) Wipe all parts with clean cloth.

(3) Allow all parts to air dry.

(4) Inspect parts for damage, wear and cracks.

(5) Replace all defective parts.

d. Assembly.

Improper installation of springs

will damage seat assembly. Care

must be taken to ensure proper

installation.

(1) Install knob (24) on rod (23).

(2) Tighten jam nut (22) on rod (23).

(3) With the aid of an assistant, install slide

assembly (21), left torsion spring (19) and

right torsion spring (20) on seat assembly (5)

with four screws (18) and locknuts (17).

(4) Install spring (16) on seat assembly (5).
TM 9-2320-364-20-5

17-110

17-40. CAB SEAT REPAIR (CONT).

(5) Install seat cover (15) on seat assembly (5) with six hooks (14).

(6) Install seat cushion (13) on seat assembly (5) with two clips (12) and screws (11).

(7) Intall spacer (10) and bushing (9) into shock absorber (4).

(8) Install shock absorber (4) on seat assembly (5) with screw (8), lockwasher (7), nut (6), screw (3),

lockwasher (2) and nut (1).

e. Installation.

Seat assembly weighs 55 lbs 

(25 kg). Attach suitable lifting

device to prevent possible injury

to personnel.

(1) With the aid of an assistant, guide seat

assembly (6) onto seat support (14) in cab

assembly (15).

(2) Install guide seat assembly (6) on studs (13)

with nuts (12).
TM 9-2320-364-20-5

 17-111

NOTE

• Only tighten locknut until

seat belt bracket can slowly

rotate.

• Ensure bushing is positioned

in seat assembly before

installation.

(3) Install seat belt (10) and tether bracket (11)

on seat assembly (6) with washer (9), screw

(8) and locknut (7).

NOTE

Tighten locknut until seat belt

bracket can slowly rotate.

(4) Install tether bracket (5) and seat belt 

bracket (4) on seat assembly (6) with 

washer (3), screw (2) and locknut (1).

f. Follow-On Maintenance:

• Check cab seat lock alignment, (Para 17-41).

• Remove wheel chocks, (TM 9-2320-363-10).

END OF TASK
TM 9-2320-364-20-5

17-112

Materials/Parts

Locknut (4) (Item 133, Appendix F)

Washer (AR) (Item 347, Appendix F)

This task covers:

a. Alignment b. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine Off (TM 9-2320-364-10)

Wheels Chocked (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanics: Automotive

(Item 74, Appendix G)

Hammer, Hand, Soft Plastic 

(Item 33, Appendix G)

Socket Set 3/8 in. (Item 62, Appendix G)

17-41. CAB SEAT LOCK ALIGNMENT PROCEDURE.

a. Alignment.

(1) Push seat lock lever (1) towards drivers cab door to release seat lock. Move seat forward or backward.

NOTE

• If seat locks upon release of seat lock lever (1) alignment is not needed.

• If seat does not lock upon release of seat lock lever (1). Perform Steps (3) through (9).

(2) Release seat lock lever (1).

(3) Remove four locknuts (2), from two screws (3) and screws (4). Discard locknuts.

(4) Using a soft faced hammer, tap the front of seat support (5).
TM 9-2320-364-20-5

 17-113

(5) Install three locknuts (2) on two screws (4) and screw (3) on tab A.

(6) Measure distance between tab B and cab floor.

NOTE

• If distance measured in Step (6) is less than 1/16 in (1.6 mm) proceed to Step (9).

• Number of washers used in Step (8) may vary depending on size of gap between tab B and

cab floor.

(7) Remove screw (3) from tab B side of seat support (5).

(8) Position washer(s) (6) between tab B and cab floor.

(9) Position screw (3) in tab B of seat support (5), and install locknut (2).

b. Follow-On Maintenance.

• Remove wheel chocks (TM9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-114

Materials/Parts

Locknut (4) (Item 133, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Cab seat removed, (Para 17-40)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

17-42. CAB SEAT SUPPORT REPLACEMENT.

a. Removal. Remove four locknuts (1), two screws (2), screws (3) and seat support (4) from cab assembly (5). 

Discard locknuts.

b. Installation. Install seat support (4) in cab assembly (5) with two screws (3), screws (2) and four locknuts (1).

c. Follow-On Maintenance:

• Install cab seat, (Para 17-40).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-115

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Seat moved to forward position,

(TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-43. CARGO NET REPLACEMENT.

NOTE

Right and left side cargo nets are

removed and installed the same

way. Right side shown.

a. Removal. Remove 15 screws (1) and cargo 

net (2) from cab shell (3).

b. Installation. Install cargo net (2) on cab shell (3) 

with 15 screws (1).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-116

Materials/Parts

Locknut (4) (Item 128, Appendix F)

Lockwasher (3) (Item 170, Appendix F)

This task covers:

a Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0-237 N.

m])

(Item 95, Appendix G)

17-44. SEAT BELT REPLACEMENT.

a. Removal.

NOTE

Both seat belts are removed the same way. Left seat is shown.

(1) Remove screw (1), lockwasher (2) and angled bracket (3) from cab assembly (4). Discard lockwasher.

(2) Remove locknut (5), screw (6), two straps (7) and washer (8) from seat assembly (9). Discard locknut.
TM 9-2320-364-20-5

 17-117

(3) Remove screw (10), lockwasher (11) and

angled bracket (12) from cab assembly (4).

Discard lockwasher.

(4) Remove locknut (13), screw (14), hardened

washer (15), seat belt bracket (16), hardened

washer (17), tether bracket (18) and 

washer (19) from seat assembly (9). Discard

locknut.

(5) Remove locknut (20), washer (21), D-ring (22), spacer (23), comfort latch (24), two hardened washers (25)

and screw (26) from cab assembly (4). Discard locknut.

(6) Remove locknut (27), screw (28), washer (29), L-bracket (30) and retractor unit (31) from cab 

assembly (4). Discard locknut.
TM 9-2320-364-20-5

17-118

17-44. SEAT BELT REPLACEMENT (CONT).

b. Installation.

NOTE

Procedure is identical for both seats. Left seat is shown.

(1) Position D-ring (22) in cab assembly (4) with two hardened washer (25), comfort latch (24), spacer (23),

washer (21), locknut (20) and screw (26).

(2) Tighten locknut (20) to 70 to 75 lb-in (8 N.

m).

(3) Install retractor unit (31) to cab assembly (4) with washer (29), screw (28), L-bracket (30) and locknut (27).

(4) Tighten locknut (27) to 70 to 75 lb-in (8 N.

m).

(5) Install tether bracket (18), hardened 

washer (17), seat belt bracket (16) and

hardened washer (19) on seat assembly (9)

with hardened washer (15) screw (14) and

locknut (13). Tighten locknut until seat belt

bracket can slowly rotate.

(6) Install angled bracket (12) on cab 

assembly (4) with lockwasher (11) and

screw (10).
TM 9-2320-364-20-5

 17-119

(7) Install hardened washer (8), two straps (7),

on seat assembly (9) with hardened 

washer (8), screw (6) and locknut (5).

Tighten locknut until buckle can slowly

rotate.

(8) Install angled bracket (3) on cab 

assembly (4) with lockwasher (2) and 

screw (1).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-120

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-45. SUNVISOR REPLACEMENT.

a. Removal. Remove four screws (1) and sunvisor (2) from cab frame (3).

b. Installation. Install sunvisor (2) on cab frame (3) with four screws (1).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-121

Materials/Parts

Locknut (2) (Item 106, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Foot rest removed, (Para 17-47)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/4 in. (Item 62, Appendix G)

Wrench, Torque (0 to 60 N.

m)

(Item 98, Appendix G)

17-46. WINDOW GUARD REPLACEMENT.

a. Removal.

(1) Remove two locknuts (1) and screws (2) from window guard (3) and frame (4). Discard locknuts.

(2) Remove window guard (3) from frame (4).

b. Installation.

(1) Position window guard (3) on frame (4).

(2) Install two screws (2) and locknuts (1) in window guard (3) and frame (4). Tighten screws to 50 lb-in 

(7 N.

m).

c. Follow-On Maintenance:

• Install foot rest, (Para 17-47).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-122

Materials/Parts

Solvent, Drycleaning (Item 87, Appendix C)

Locknut (4) (Item 106, Appendix F)

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical and Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

17-47. FOOT REST REPAIR.

a. Removal.

(1) Push foot rest (1) upward to access two screws (2).

(2) Remove two locknuts (3) and screws (2) from window guard (4). Discard locknuts.

(3) Remove foot rest (1) from window guard (4).
TM 9-2320-364-20-5

 17-123

b. Disassembly.

(1) Remove two locknuts (1), screws (2) and

retainer (3) from footrest (4). Discard

locknuts.

(2) Remove footrest bracket (5) from foot

rest (4).

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc).

Failure to comply may result in injury or death to personnel.

(1) Clean all metal parts with drycleaning solvent.

(2) Dry metal parts with compressed air.

(3) Inspect metal parts for breaks, cracks and 

sharp edges.

(4) Replace all damaged parts.
TM 9-2320-364-20-5

17-124

17-47. FOOT REST REPAIR (CONT).

d. Assembly.

(1) Position footrest bracket (5) on footrest (4).

(2) Install retainer (3), two screws (2) and nuts

(1) on footrest bracket (5) and footrest (4).

e. Installation.

(1) Position footrest (1) on window guard (4).

NOTE

Ensure footrest mounting screws

are not over-tightened. Footrest

mounting screws are tightened

only enough to ensure footrest

still moves freely.

(2) Install two screws (2) and locknuts (3) in

window guard (4).

(3) Push footrest (1) down on window guard (4).

f. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-125

Materials/Parts

Screw, Tapping (Item 318, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-48. CAB FLOOR DRAIN PLUG REPLACEMENT.

a. Removal.

NOTE

There are two cab floor drain plugs, one under each seat. Left side is shown.

(1) Turn handle (1) counter clockwise and remove cab floor drain plug (2) from cab floor (3).

(2) Remove screw (4) and chain (5) from cab floor (3). Discard screw.

b. Installation.

(1) Install chain (5) with screw (4) to cab floor (3).

(2) Install cab floor drain plug (2) in cab floor (3) and turn handle (1) clockwise.

c. Follow-On Maintenance.

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

DOOR

SHOWN

REMOVED

FOR CLARITY

1

3

2

5

4
TM 9-2320-364-20-5

17-126

Materials/Parts

Locknut (2) (Item 133, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Heater compartment access panel removed,

(Para 17-4)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-49. HEATER CONTROL SIDE PANEL GRAB HANDLE REPLACEMENT.

a. Removal. Remove two locknuts (1), screws (2) and grab handle (3) from heater control side panel (4). 

Discard locknuts.

b. Installation. Install grab handle (3) with two screws (2) and locknuts (1) on heater control side panel (4).

c. Follow-On Maintenance:

• Install heater compartment access panel, (Para 17-4).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-127

Materials/Parts

Locknut (2) (Item 133, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-50. GLOVE BOX GRAB HANDLE REPLACEMENT.

a. Removal.

(1) Open latch (1) and open glove box door (2).

(2) Remove two locknuts (3), screws (4) and grab handle (5) from glove box (6). Discard locknuts.

b. Installation.

(1) Install grab handle (5) with two screws (4) and locknuts (3) on glove box (6).

(2) Close glove box (2) and secure latch (1).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-128

Materials/Parts

Locknut (2) (Item 140, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automatic

(Item 74, Appendix G)

17-51. INSTRUMENT PANEL GRAB HANDLE REPLACEMENT.

a. Removal. Remove two locknuts (1), screws (2) and grab handle (3) from dash (4). Discard locknuts.

b. Installation. Install grab handle (3) with two screws (2) and locknuts (1) on dash (4).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-129

Materials/Parts

Locknut (2) (Item 140, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-52. SIDE CAB GRAB HANDLE REPLACEMENT.

NOTE

• Left side grab handle will have a longer screw and rifle mount bracket on bottom screw.

• Both handles are removed the same. Left side shown.

a. Removal. Remove two locknuts (1), rifle mount (2), screw (3), screw (4) and grab handle (5) from cab (6). 

Discard locknuts.

b. Installation. Install grab handle (5) and rifle mount (2) with screw (4), screw (3) and two locknuts (1) 

on cab (6).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

1 3

5

1 2

4

6

DOOR

SHOWN

REMOVED

FOR CLARITY
TM 9-2320-364-20-5

17-130

Materials/Parts

Adhesive (Item 5, Appendix C)

Gasket, Strip (Item 40, Appendix C)

Locknut (11) (Item 110, Appendix F)

Lockwasher (Item 151, Appendix F)

Tenz Nut (2) (Item 219, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-53. GLOVE BOX REPLACEMENT.

a. Removal.

(1) Open glove box door and remove three screws (1), locknuts (2) and plate (3) from dash (4). Discard

locknuts.

(2) Remove four screws (1), locknuts (2) and glove box (5) from dash (4). Discard locknuts.
TM 9-2320-364-20-5

 17-131

(3) Remove four screws (6), locknuts (7) and

glove box door (8) from dash (4). Discard

locknuts.

(4) Remove two screws (9), tenz nuts (10) and

bracket (11) from glove box door (8).

Discard tenz nuts.

(5) Remove two screws (6), locknuts (7) and

striker (12) from dash (4). Discard locknuts.

(6) Remove screw (13), nut (14), lockwasher

(15) and bracket (16) from dash (4). Discard

lockwasher.

(7) Remove gasket strip (17) from dash (4).

Discard gasket strip.

b. Installation.

Adhesives, sovents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a wellventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(1) Apply adhesive to back of gasket strip (17).

NOTE

Use glove box door as a template

to install and trim corners of

gasket strip.

(2) Install gasket strip (17) on dash (4).

(3) Install bracket (16), screws (13), lockwasher

(15) and nut (14) in dash (4).

(4) Install striker (12), two screws (6) and

locknuts (7) in dash (4).
TM 9-2320-364-20-5

17-132

17-53. GLOVE BOX REPLACEMENT (CONT).

(5) Install bracket (11), two screws (9) and tenz

nuts (10) in glove box door (8).

NOTE

Ensure glove box door is

positioned to full right and will

not hit first aid kit when opening

or closing glove box door.

(6) Install glove box door (8), four screws (6)

and locknuts (7) in dash (4).

(7) Install glove box (5), four screws (1) and locknuts (2) in dash (4).

(8) Install plate (3), three screws (1) and locknuts (2) in dash (4).

(9) Close glove box door.

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-133

Materials/Parts

Adhesive Sealant (Item 14, Appendix C)

Sealing Compound (Item 80, Appendix C)

Locknut (Item 91, Appendix F)

Locknut (6) (Item 92, Appendix F)

Locknut (2) (Item 93, Appendix F)

Locknut (2) (Item 106, Appendix F)

Locknut (6) (Item 133, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

LHS fully extended, (TM 9-2320-364-10)

Decontamination bracket removed (if equipped),

(Para 24-3)

Auxiliary fuel tank removed (if equipped),

(Para 15-24)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Wrench, Combination 1-1/8 in.

(Item 79, Appendix G)

17-54. STOWAGE BOX AND BRACKET REPLACEMENT.

Materials/Parts - Continued

Seal, Door (Item 329, Appendix F)

a. Removal.

NOTE

• If removing door panel assembly only, perform Steps (1) through (3).

• If removing box assembly only, perform Steps (4) through (10).

(1) Remove six locknuts (1), screws (2) and door panel assembly (3) from box assembly (4). Discard

lockwashers.

(2) Remove door seal (5) from box assembly (4). Discard door seal.

(3) Remove six locknuts (6), screws (7) and water guard (8).
TM 9-2320-364-20-5

17-134

17-54. STOWAGE BOX AND BRACKET REPLACEMENT (CONT).

NOTE

Step (4) is for self recovery winch

equipped trucks only.

(4) Remove two locknuts (9), screws (10) and

separate two cushion clamps (11) from box

assembly (4). Discard locknuts.

(5) If necessary for replacement, remove two

bleeder valves (12) from box assembly (4).

(6) Remove two locknuts (13), washers (14),

springs (15) and screws (16). Discard

locknuts.

(7) Remove two locknuts (17) and screws (18).

Discard locknuts.

Box assembly weighs 92 lbs

(42 kg). Ensure box assembly 

is properly supported to prevent

possible injury to personnel.

(8) With the aid of an assistant, remove box

assembly (4) from left hand brackets (19)

and right hand bracket (20).
TM 9-2320-364-20-5

 17-135

(9) With the aid of an assistant, remove two

locknuts (21), screws (22) and (23) and LH

bracket (19). Discard locknuts.

(10) With the aid of an assistant, remove two

locknuts (24), screws (25) and RH

bracket (20). Discard locknuts.

b. Installation.

NOTE

• If installing box assembly only,

perform Steps (1) through (9).

• If installing door panel

assembly only, perform Steps

(10) through (12).

(1) With the aid of an assistant, install RH

bracket (20) with two screws (25) and

locknuts (24).

(2) With the aid of an assistant, install LH

bracket (19) with two screws (22) and (23)

and locknuts (21).

Box assembly weighs 92 lbs

(42 kg). Ensure box assembly 

is properly supported prior to

installation to prevent possible

injury to personnel.

(3) With the aid of an assistant, install box

assembly (4) on two brackets (19) and (20).

(4) Install two screws (18) and locknuts (17).

(5) Install two screws (16), springs (15),

washers (14) and locknuts (13). Tighten

locknuts until spring height is 2-3/4 in.

(69.85 mm).
TM 9-2320-364-20-5

17-136

17-54. STOWAGE BOX AND BRACKET REPLACEMENT (CONT).

(6) If removed, install two bleeder valves (12)

on box assembly (4).

NOTE

Step (7) is for self recovery winch

equipped trucks only.

(7) Install two cushion clamps (11) on box

assembly (4) with two screws (10)

and locknuts (9).

NOTE

Step (8) is for trucks equipped

with auxiliary fuel tanks only.

(8) Grind off end of water guard (8), if

necessary, for water guard to clear fuel tank

brackets.

(9) Install water guard (8), six screws (7) and

locknuts (6).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(10) Coat new door seal seam (5) with adhesive.

NOTE

Install door seal so that seam of

door seal is on bottom side of 

box assembly.

(11) Install door seal (5) on box assembly (4).

(12) Install door panel assembly (3) on box

assembly (4) with six screws (2) and

locknuts (1).

(13) Apply sealing compound to hinge edges of

door panel assembly (3).
TM 9-2320-364-20-5

 17-137

c. Follow-On Maintenance:

• Install auxiliary fuel tank (if equipped), (Para 15-24).

• Install decontamination bracket (if equipped), (Para 24-3).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-138

Materials/Parts

Adhesive (Item 6, Appendix C)

Solvent, Drycleaning (Item 87, Appendix C)

This task covers:

a. Removal b. Disassembly c. Cleaning/Inspection

d. Assembly e. Installation f. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

17-55. CRANE STOWAGE BOX REPAIR.

Materials/Parts - Continued

Locknut (4) (Item 96, Appendix F)

Locknut (2) (Item 134, Appendix F)

Seal (Item 327, Appendix F)

a. Removal.

(1) Lift two rubber latches (1) and open stowage box door (2).

(2) Remove four locknuts (3), screws (4) and stowage box (5) from crane frame (6). Discard locknuts.
TM 9-2320-364-20-5

 17-139

b. Disassembly.

(1) Remove two locknuts (1), screws (2) and

rubber latches (3) from stowage box (4).

Discard locknuts.

(2) Remove seal (5) from stowage box (4).

Discard seal.

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc).

Failure to comply may result in injury or death to personnel.

(1) Wash all metal parts in drycleaning solvent.

(2) Dry all metal parts with compressed air.

(3) Inspect metal parts for breaks, cracks and sharp edges.

(4) Replace all damaged parts.
TM 9-2320-364-20-5

17-140

17-55. CRANE STOWAGE BOX REPLACEMENT (CONT).

d. Assembly.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and water.

NOTE

Seal should be cut to 47 in. (119

cm) length.

(1) Coat lip of seal (5) with adhesive and install

seal on stowage box (4).

(2) Install two rubber latches (3) with screws (2)

and locknuts (1).

e. Installation.

(1) Position stowage box (5) on crane frame (6).

(2) Install four screws (4) and locknuts (3).

(3) Close stowage box door (2) and fasten two

rubber latches (1).

f. Follow-On Maintenance:

• Remove wheel chocks, (TM 9 2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 17-141

Materials/Parts

Locknut (2) (Item 106, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-56. FIRST AID KIT BRACKET REPLACEMENT.

a. Removal. Remove two screws (1), locknuts (2) and first aid bracket kit (3) from dash (4).

b. Installation. Install first aid kit bracket (3) with two screws (1) and locknuts (2) in dash (4).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-142

Materials/Parts

Locknut (2) (Left Side) (Item 106, Appendix F)

Locknut (2) (Left Side) (Item 120, Appendix F)

Lockwasher (4) (Left Side)

(Item 171, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Torque (0 to 60 N.

m)

(Item 98, Appendix G)

17-57. RIFLE STOWAGE BRACKETS REPLACEMENT.

Materials/Parts - Continued

Lockwasher (8) (Right Side)

(Item 171, Appendix F)

Quickedge (Item 289, Appendix F)

Screw, Self-Locking (Left Side)

(Item 315, Appendix F)

a. Removal.

NOTE

Steps (1) through (7) are for left side cab.

(1) Remove screw (1), locknut (2) and support (3) from grab handle (4). Discard locknut.

(2) Remove two screws (5), lockwashers (6), nuts (7) and bracket (8) from support (3). Discard lockwashers.

(3) Remove clip (9) from catch (10) and bracket (8).
TM 9-2320-364-20-5

 17-143

(4) Remove two screws (11) and locknuts (12) from rifle stock support (13) and cab frame (14). Discard

locknuts.

(5) Remove screw (15) and rifle stock support (13) from cab frame (14). Discard screw.

(6) Remove two screws (16), lockwashers (17), nuts (18) and rifle support (19) from rifle stock support (13).

Discard lockwashers.

NOTE

If quickedge is damaged, perform Step (7).

(7) Remove quickedge (20) from rifle support (19).
TM 9-2320-364-20-5

17-144

17-57. RIFLE STOWAGE BRACKETS REPLACEMENT (CONT).

NOTE

Steps (8) through (12) are for right side door.

(8) Remove two nuts (21), lockwashers (22), screws (23) and rifle support (24) from bracket (25). Discard

lockwashers.

(9) Remove two screws (26), lockwashers (27), washers (28) and bracket (25) from door assembly (29).

Discard lockwashers.

NOTE

If quickedge is damaged, perform Step (10).

(10) Remove quickedge (30) from rifle support (24).

(11) Remove two screws (31), lockwashers (32), washers (33), angle bracket (34) and boot (35) from door

assembly (29). Discard lockwashers.

(12) Remove two screws (36), lockwashers (37), nuts (38), rifle catch (39) and catch bracket (40) from angle

bracket (34). Discard lockwasher.
TM 9-2320-364-20-5

 17-145

b. Installation.

NOTE

Steps (1) through (5) are for right side cab.

(1) Install catch bracket (40) and rifle catch (39) on angle bracket (34) with two screws (36), lockwashers (37)

and nuts (38).

(2) Install boot (35) and angle bracket (34) with two washers (33), lockwashers (32) and screws (31) on door

assembly (29).

NOTE

If quickedge was removed, perform Step (3).

(3) Install quickedge (30) on rifle support (24).

(4) Install bracket (25) with two washers (28), lockwashers (27) and screws (26) on door assembly (29).

Tighten screws to 100 lb-in (11 N.

m).

(5) Install rifle support (24) with two screws (23), lockwashers (22) and nuts (21) on bracket (25). Tighten

nuts to 100 lb-in (11 N.

m).
TM 9-2320-364-20-5

17-146

17-57. RIFLE STOWAGE BRACKETS REPLACEMENT (CONT).

NOTE

• Steps (6) through (12) are for left side cab.

• If quickedge was removed, perform Step (6).

(6) Install quickedge (20) on rifle support (19).

(7) Install rifle support (19) with two screws (16), lockwashers (17) and nuts (18) on rifle stock support (13).

Tighten nuts to 100 lb-in (11 N.

m).

(8) Install screw (15) on rifle stock support (13).

(9) Install rifle stock support (13) with two screws (11) and locknuts (12) on cab frame (14). Tighten nuts to

100 lb-in (11 N.

m).
TM 9-2320-364-20-5

 17-147

(10) Install clip (9) on catch (10) and bracket (8).

(11) Install bracket (8) on support (3) with two screws (5), lockwashers (6) and nuts (7).

(12) Install support (3) on grab handle (4) with screw (1) and locknut (2).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-148

Materials/Parts

Locknut (Item 110, Appendix F)

Locknut (2) (Item 133, Appendix F)

Locknut (Item 134, Appendix F)

Locknut (Item 140, Appendix F)

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Ladder removed, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Vise, Machinist’s (Item 75, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0 to 237 N.

m])

(Item 95, Appendix G)

17-58. LADDER SUPPORT REPAIR.

NOTE

There are two ladder supports. Both ladder supports are removed the same way.

a. Removal. Remove screw (1), locknut (2) and ladder support (3) from truck (4). Discard locknut.
TM 9-2320-364-20-5

 17-149

b. Disassembly.

(1) Remove two locknuts (5), screws (6) and

hook support (7) from ladder support (3).

Discard locknuts.

(2) Remove locknut (8), screw (9) and latch

hood (10) from retaining strap (11). Discard

locknut.

(3) Remove locknut (12), screw (13) and

retaining strap (11) from ladder support (3).

Discard locknut.

c. Cleaning/Inspection.

(1) Inspect latch hood for cracks.

(2) Inspect all weldments for cracks or dents.

(3) Inspect ladder support for cracks or damage.

(4) Replace all damaged parts.

d. Assembly.

(1) Install retaining strap (11), screw (13) and

locknut (12) on ladder support (3). Tighten

screw to 23 lb-ft (31 N.

m).

(2) Install latch hood (10), screw (9) and locknut

(8) on retaining strap (11). Tighten until

three threads are showing.

(3) Install support hook (7), two screws (6) and

locknuts (5) on ladder support (3).

e. Installation. Install support (3), screw (1)

and locknut (2) on truck (4). Tighten to 30

lb-ft (41 N.

m).

f. Follow-On Maintenance:

• Install ladder, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-150

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Drill, Electric, Portable (Item 11, Appendix G)

Drill Set, Twist (Item 28, Appendix G)

Tool Kit, Blind Rivet (Item 72, Appendix G)

17-59. THREADED SCREW INSERT REPLACEMENT.

NOTE

• All threaded screw inserts are replaced the same way. Door threaded screw insert is shown.

• When replacing threaded screw inserts, refer to Table 17-1 to determine which twist drill to

use.

Table 17-1. Threaded Screw Insert Replacement Parts.

Part Number

Twist Drill

Size (In.) Thread Size

2025970 25/64 .25 - 20

2025980 25/64 .25 - 20

2025990 19/64 .10 - 24

2026010 17/32 .31 - 18

2026020 17/32 .31 - 18
TM 9-2320-364-20-5

 17-151

When drilling out threaded screw

insert do not enlarge existing

hole. The new threaded screw

insert will not seat properly if

hole is enlarged.

a. Removal. Drill out threaded screw insert (1).

b. Installation. Install threaded screw insert (1) in hole.

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

17-152

This task covers:

a. Adjustment b. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

17-60. STOWAGE BOX/ENGINE COVER LATCH ADJUSTMENT.

a. Adjustment.

NOTE

To tighten latch, do Steps (1)

through (3). To loosen latch, do

Steps (4) through (6).

(1) Loosen nut (1) away from latching

device (2).

(2) Tighten nut (3).

(3) Repeat Steps (1) and (2) until stowage box

door (4) latches properly.

(4) Loosen nut (3) and lockwasher (5) away

from latching device (2).

(5) Tighten nut (1).

(6) Repeat Steps (4) and (5) until stowage box

door latches properly.

(7) Proper engine cover adjustment is achieved

when .12 in. (3.17 mm) of play is felt

between engine cover and striker.

b. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 18-1

CHAPTER 18

MATERIAL HANDLING CRANE (MHC),

SELF-RECOVERY WINCH (SRW) AND 

LOAD HANDLING SYSTEM (LHS) MAINTENANCE

Para Contents Page

18-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1

18-2 Boom Sheave Replacement 18-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18-3 Boom Wear Pads Inspection/Replacement 18-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18-4 Crane Remote Control Box Repair 18-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18-5 Crane Hoist Cable Replacement 18-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18-6 Retainer Bar/Roller Replacement 18-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18-7 Crane Angle Indicator Replacement 18-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18-8 Crane Hook Block, Hook and Clevis Repair 18-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18-9 Auxiliary Hand Pump Repair 18-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18-10 Crane Accumulator Replacement 18-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18-11 Crane Hydraulic Hoses, Tubes and Fittings Replacement 18-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18-12 Self-Recovery Winch (SRW) Replacement 18-63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18-13 Self-Recovery Winch (SRW) Front Tension Guide Repair 18-68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18-14 Self-Recovery Winch (SRW) Front Guide Replacement 18-73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18-15 Self-Recovery Winch (SRW) Rear Tension Guide Repair 18-75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18-16 Self-Recovery Winch (SRW) Rear Guide Replacement 18-81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18-17 Self-Recovery Winch (SRW) Cable Replacement 18-83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18-18 Outrigger Pads Repair 18-86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18-1. INTRODUCTION.

This chapter contains maintenance instructions for removing, replacing, installing and adjusting components of the

Self-Recovery Winch (SRW), Material Handling Crane (MHC) and Load Handling System (LHS) as authorized by 

the Maintenance Allocation Chart (MAC) at the Unit Maintenance level.
TM 9-2320-364-20-5

18-2 

Materials/Parts

Oil, Lubricating (Item 54, Appendix C)

Lockwasher (Item 200, Appendix F)

Washer, Key (Item 350, Appendix F)

This task covers:

a. Removal c. Installation

b. Cleaning/Inspection d. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Hoist cable removed, (Para 18-4)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

Pliers, Retaining Ring (Item 49, Appendix G)

Socket Set, 3/4 in. (Item 62, Appendix G)

Wrench, Combination 1-1/8 in.

(Item 79, Appendix G)

Wrench, Torque (0 to 600 lb-ft [0 to 814 N.

m])

(Item 97, Appendix G)

18-2. BOOM SHEAVE REPLACEMENT.

a. Removal.

(1) Straighten tines of lock ring (1) and remove nut (2) and key washer from shaft (3). Discard key washer.

(2) Remove screw (4), lockwasher (5), washer (6) and lock pin (7) from fly section (8). Discard lockwasher.

(3) Remove bushing (9) from lock pin (7).

(4) Remove shaft (3), sheave (10) and spacer (11) from fly section (8).

(5) Remove lube fitting (12) from shaft (3).
TM 9-2320-364-20-5

 18-3

Use care when removing

retaining rings. Retaining rings

are under spring tension and can

act as projectiles when released

and could cause severe eye injury.

Bearings may fall from races

upon removal if care is not taken,

and damage to equipment may

result.

(6) Remove retaining ring (13), two bearings

(14) and spacer (15) from sheave (10).

NOTE

Perform Step (7) if bushings are

damaged.

(7) Remove two bushings (16) and retaining ring (17) from sheave (10).

b. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc).

Failure to comply may result in injury or death to personnel.

(1) Clean all metal parts with drycleaning solvent.

(2) Allow bearing to air dry, then coat with lubricating oil.

(3) Dry metal parts with compressed air.

(4) Inspect metal parts for breaks, cracks and sharp edges.

(5) Inspect bearing for loose rollers or cracked and broken races.

(6) Replace all damaged parts.
TM 9-2320-364-20-5

18-4 

18-2. BOOM SHEAVE REPLACEMENT (CONT).

c. Installation.

NOTE

Perform Step (1) if bushings 

were removed.

(1) Install retaining ring (17) and two

bushings (16) in sheave (10).

Use care when installing 

retaining rings. Retaining rings 

are under spring tension and can

act as projectiles when released 

and could cause severe eye injury.

(2) Install spacer (15), bearings (14) and

retaining ring (13) in sheave (10).

(3) Install lube fitting (12) in shaft (3).

(4) Install sheave (10) and spacer (11) in fly

section (8) with shaft (3).

(5) Install bushing (9) in lock pin (7).

(6) Install sheave (10) with lock pin (7), washer

(6), lockwasher (5) and screw (4) in fly

section (8). Tighten screw to 225 lb-ft 

(305 N.

m).

(7) Install key washer (1) and nut (2) in pin (3) 

and bend tines of key washer into slots in

nut.

d. Follow-On Maintenance:

• Install cable, (Para 18-4).

• Lubricate fittings, (Para 2-9).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 18-5

This task covers:

a. Inspection c. Installation

b. Removal d. Follow-On Maintenance

INITIAL SETUP

Materials/Parts

Grease (Item 42, Appendix C)

Sealing Compound (Item 74, Appendix C)

Sealing Compound (Item 77, Appendix C)

Tags, Identification (Item 88, Appendix C)

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheel chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Drill Set, Twist

(Item 19, Appendix G)

Jackstand (Item 42, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0 to 237 N.

m])

(Item 95, Appendix G)

18-3. BOOM WEAR PADS INSPECTION/REPLACEMENT.

a. Inspection.

Ensure boom does not contact

LHS hook arm or damage to

equipment may result.

NOTE

• Ensure boom is not supported

or binding.

• There are three sets of wear

pads.

• Do all inspections of boom

wear pads in a. Inspection

before proceeding to b.

Removal.

(1) Fully extend boom (1) over stowage box (2).
TM 9-2320-364-20-5

18-6 

18-3. BOOM WEAR PADS INSPECTION/REPLACEMENT (CONT).

NOTE

• If measurement in Step (2) is

less than 1/32 in. (.8 mm),

replace wear pads.

• Wear pads must be replaced in

pairs.

(2) Measure and record distance between two

inner-mid section wear pad retainers (3) and

bottom of fly section (4). (Measurement A).

NOTE

• If measurement in Step (3) is

more than 1/8 in. (3.2 mm),

replace wear pads.

• Wear pads must be replaced in

pairs.

(3) Measure and record distance lower edge of

fly section (4) has worn into sides of two

wear pads (5). (Measurement B).

(4) Repeat Steps (2) and (3) for outer-mid

section and boom base section.

NOTE

• If measurement in Step (5) is

more than 1/8 in. (3.2 mm) or

less than 1/16 in. (1.6 mm),

shims must be added or

subtracted or wear pads

replaced. Wear pad clearance

should be reinspected.

• Proper shim size for each wear

pad is determined by dividing

measurement “C” by two.

• Boom must be positioned tight

up against opposite wear pad

being measured.

(5) Measure and record distance between lower

edge of fly section (4) and wear pad (5).

(Measurement C).

(6) Repeat Step (5) for outer-mid section and

boom base section.

5

3

4

1/8 IN. MAX

(3.2 MM)

1/8 IN. MAX

(3.2 MM)

1/32 IN. MAX

(.8 MM)
TM 9-2320-364-20-5

 18-7

NOTE

• If measurement in Step (7) is

not between 1/16 in. (1.6

mm) and 1/8 in. (3.2 mm),

shims must be added or wear

pad replaced.

• If wear pad thickness is less

than 1/4 in. (6.35 mm),

replace wear pad.

(7) Measure and record distance between wear

pad (6) and top of fly section (4).

(Measurement D).

(8) Measure and record thickness of wear pad

(6). (Measurement E).

(9) Repeat Steps (7) and (8) for outer-mid

section and boom base section.

b. Removal.

Ensure boom does not contact

LHS hook arm or damage to

equipment may result.

NOTE

• There are three sets of wear

pads. They are removed the

same way. Inner-mid and

fly section are shown.

• Ensure boom is not

supported or binding.

(1) Fully extend boom (1) and position over

stowage box (2).

NOTE

• Wear pad may have shims.

• Note location and number of

shims during removal.

• Wear pad in Step (2) must be

removed to allow removal of

wear pads in Step (5).

• Tag and mark screws after

removal.

(2) Remove two screws (3), washers (4), 

shim (5) and wear pad (6) from inner-mid

section (7).

(3) Repeat Step (2) for outer-mid section and

boom base section.

4

MEASUREMENT ”D” MEASUREMENT ”E”

5

6

3

4

7

6
TM 9-2320-364-20-5

18-8 

18-3. BOOM WEAR PADS INSPECTION/REPLACEMENT (CONT).

Do not apply excessive force on

jackstand with boom. Only allow

weight of boom to lift boom off

of bottom of wear pads. Failure

to comply may result in damage

to equipment.

NOTE

• Hook block may need to be

lowered to clear jackstand.

• Lower boom until top of fly

section contacts inside top of

inner mid section.

(4) Position end of boom (1) on jackstand.

Do not put fingers in between

boom sections when removing

wear pads. Use a screwdriver or

similar tool to remove wear pads.

Failure to comply may result in

injury to personnel.

NOTE

• Wear pads are removed by

sliding towards center of

inner-mid section.

• Note location and position

of wear pads after removal.

• There are three sets of wear

pads. They are removed the

same way. Inner-mid and

fly section are shown.

(5) Remove two wear pads (8) from inner-mid

section (7) and fly section (9).

1

JACKSTAND

9

8

7
TM 9-2320-364-20-5

 18-9

NOTE

• Wear pads may have shims.

• Perform Step (6) if wear pads

have shims.

• Note location and number of

shims after removal.

(6) Remove screw (10) and shim(s) (11) from

two wear pads (8).

(7) Repeat Steps (5) and (6) for outer-mid

section and boom base section.

c. Installation.

Adhesives, solvents and sealing compounds can burn easily, can give off harmful vapors and

are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use

in well-ventilated area. If adhesive, solvent or sealing compound gets on skin or clothing,

wash immediately with soap and water.

If installing new wear pad or changing shim amount or size, screw must not protrude

through back of wear pad or damage to equipment may result.

NOTE

• Install shims as noted during removal.

• Beveled side of shim faces away from wear pad.

• Wear pad may or may not require shims.

• Perform Steps (1) and (2) if wear pads have shims.

• There are three sets of wear pads. They are installed the same way. Inner-mid and fly section

are shown.

(1) Apply sealing compound to threads of two screws (10).

(2) Install shim(s) (11) and two screws (10) on wear pads (8).

(3) Apply grease to contact surface of two wear pads (8).

8 11 10
TM 9-2320-364-20-5

18-10 

18-3. BOOM WEAR PADS INSPECTION/REPLACEMENT (CONT).

Do not put fingers in between

boom sections when installing

wear pads. Use a screwdriver or

similar tool. Failure to comply

may result in injury to personnel.

NOTE

Wear pads are positioned between

two wear pad retainers.

(4) Install two wear pads (8) in inner-mid

section (7) and fly section (9).

(5) Repeat Steps (1) through (4) for outer-mid

section and boom base section.

NOTE

• Wear pads must be fully seated

against outer edge of inner-mid

section.

• Ensure fly section seats in

wear pads.

(6) Raise boom (1) up off of jackstand. 1

JACKSTAND

9

8

7
TM 9-2320-364-20-5

 18-11

Adhesives, solvents and sealing

compounds can burn easily, can

give off harmful vapors and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

If installing new wear pad or

changing shim amount or size,

ensure correct screw is installed.

Screw must not protrude through

wear pad and wear pad must fit

tight or damage to equipment

may result.

NOTE

Wear pad may or may not require

shims.

(7) Apply sealing compound to threads of two

screws (3).

(8) Install wear pad (6), shim(s) (5), two

washers (4) and screws (3) to inner-mid

section (7). Tighten screws (3) to 31 lb-ft

(42 N.

m).

(9) Apply grease to wear pad (6).

(10) Repeat Steps (7) through (9) for outer-mid

section and boom base section.

d. Follow-On Maintenance:

• Load test crane, (TM 9-2320-364-34-2).

• Stow crane, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

5

6

3

4

7
TM 9-2320-364-20-5

18-12 

Materials/Parts

Adhesive (Item 6, Appendix C)

Adhesive (Item 10, Appendix C)

Silicone Compound (Item 84, Appendix C)

Solvent, Drycleaning (Item 87, Appendix C)

Tags, Identification (Item 88, Appendix C)

Gasket (Item 64, Appendix F)

Locknut (16) (Item 119, Appendix F)

Lockwasher (3) (Item 150, Appendix F)

Lockwasher (Item 155, Appendix F)

Packing, Preformed (Item 247, Appendix F)

Washer, Plastic (2) (Item 351, Appendix F)

Washer, Rubber (Item 352, Appendix F)

This task covers:

a. Disassembly c. Assembly

b. Cleaning/Inspection d. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Control box removed from storage box,

(TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, Electric (Item 73, Appendix G)

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Drill, Electric, Portable (Item 17, Appendix G)

Drill Set, Twist (Item 19, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

Tool Kit, Blind Rivet (Item 72, Appendix G)

Wrench, Combination, 1-11/16 in.

(Item 85, Appendix G)

18-4. CRANE REMOTE CONTROL BOX REPAIR.

a. Disassembly.

NOTE

• Tag and mark all 

connectors, switches and

wires prior to removal.

• All controllers are removed

the same way.

(1) Remove shoulder strap (1) from remote

control box (2).
TM 9-2320-364-20-5

 18-13

(2) Remove four locknuts (3) from studs (4).

Discard locknuts.

(3) Lift swing controller (5) away from box (2).

(4) Disconnect swing controller connector (6)

from connector (7).

(5) Remove gasket (8) and swing controller (5)

from box (2). Discard gasket.

NOTE

Note position of screw and lever

assembly prior to removal.

(6) Note position and remove screw (9), lever

assembly (10) and preformed packing (11)

from swing controller (5). Discard

preformed packing.

(7) Loosen nut (12) and remove knob (13) and

nut (12) from lever assembly (10).

(8) Repeat Steps (2) through (7) for telescope

controller, hoist controller and boom

controller.
TM 9-2320-364-20-5

18-14 

18-4. CRANE REMOTE CONTROL BOX REPAIR (CONT).

(9) Disconnect switch (14) from connector (15).

(10) Remove two screws (16), switch (14) and

insulator (17) from controller (18).

(11) Disconnect switch (19) from connector

(20).

(12) Remove two screws (21), switch (19),

insulator (22) and spacer (23).

NOTE

Do not remove spacer from

circuit board if circuit board is not

being replaced.

(13) Remove screws (24) and (25), lockwashers

(26), heat sink (27) and spacer (28) from

circuit board (29). Discard lockwashers.

(14) Remove circuit board (29) from

controller (18).

NOTE

If circuit board is not being

replaced, go to Step (16).

(15) Remove heat sink (30) from circuit

board (29).

(16) Repeat Steps (9) through (15) for telescope

controller, hoist controller and boom

controller.

(17) Remove locknut (31), washer (32),

chain (33) and washer (34) from stud (35).

Discard locknut and plastic washers.

(18) Remove cap (36) then note position and

remove nut (37) and lockwasher (38) from

receptacle (39). Discard lockwasher.

(19) Push receptacle (39) into box (2) and

remove rubber washer (40). Discard rubber

washer.
TM 9-2320-364-20-5

 18-15

(20) Lift switch guard (41) and mark position.

(21) Remove nut (42), switch guard (41), nylon

washer (43), rubber washer (44) and washer

(45) from ON/OFF switch (46).

(22) Pull ON/OFF switch (46) out of box (2)

through controller hole.

(23) Remove four connectors (47) from ON/OFF

switch (46).

(24) Remove ground wire (48) from ground

terminal (49).

(25) Remove wire harness (50) from box (2).

NOTE

Perform Step (26) only if data

plate is damaged, or if replacing

box.

(26) Drill out and remove four rivets (51), data

plate (52) and ground terminal (49) from

box (2).
TM 9-2320-364-20-5

18-16 

18-4. CRANE REMOTE CONTROL BOX REPAIR (CONT).

b. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc).

Failure to comply may result in injury or death to personnel.

(1) Clean all metal parts with drycleaning solvent.

(2) Dry metal parts with compressed air.

(3) Inspect for broken wires and connectors, cracks, and broken welds.

(4) Replace all damaged parts.

c. Assembly.

NOTE

Perform Step (1) only if data

plate was removed.

(1) Install data plate (52) and ground terminal

(48) on box (2) with four rivets (51).

(2) Position wiring harness (50) in box (2).

(3) Install with ground wire (48) on ground

terminal (49).
TM 9-2320-364-20-5

 18-17

(4) Install four connectors (47) on ON/OFF

switch (46).

NOTE

OFF position of switch points to

rubber key of washer.

(5) Install ON/OFF switch (46) in box (2) with

washer (45), rubber washer (44), nylon

washer (43), switch guard (41), lockwasher

(44) and nut (42).

(6) Install rubber washer (40) and

receptacle (39) in box (2) with

lockwasher (38) and nut (37).

(7) Install cap (36) on receptacle (39).

(8) Install plastic washer (34), chain (33) and

plastic washer (32) on stud (35) with

locknut (31).

NOTE

If circuit board was not replaced,

go to Step (10).

(9) Position heat sink (30) on circuit board (29).

(10) Install circuit board (29) on controller (18).

NOTE

Spacer is installed only if circuit

board was replaced.

(11) Install spacer (28) and heat sink (27) on

circuit board (29) with three lockwashers

(26) and screws (24) and (25).
TM 9-2320-364-20-5

18-18 

18-4. CRANE REMOTE CONTROL BOX REPAIR (CONT).

(12) Install spacer (23), insulator (22) and

switch (19) on controller (18) with two

screws (21).

(13) Connect connector (20) on switch (19).

(14) Install insulator (17) and switch (14) on

controller (18) with two screws (16).

(15) Connect connector (15) on switch (14).

(16) Repeat Steps (12) through (15) for

telescope controller, hoist controller and

boom controller.

(17) Install nut (12) and knob (13) on swing

control lever assembly (10).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(18) Apply silicone compound to shaft (53) on

swing control lever assembly (10).

(19) Install preformed packing (11) on swing

control lever assembly (10).

(20) Apply adhesive to underside of head on

screw (9).

(21) Install swing control lever assembly (10) on

swing controller (5) with screw (9).
TM 9-2320-364-20-5

 18-19

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent, or sealing compound

gets on skin or clothing, wash

immediately with soap and

water.

(22) Coat both sides of gasket (8) with adhesive

and install gasket on swing controller (5).

(23) Connect swing controller connector (6) to

connector (7).

(24) Install swing controller (5) on studs (4) and 

box (2) with four locknuts (3).

NOTE

The inner two valve assemblies

must be installed before the outer

two valve assemblies.

(25) Repeat steps (17) through (24) for telescope

controller, hoist controller and boom

controller in that order.

(26) Install shoulder strap (1) on box (2).

d. Follow-On Maintenance:

• Operate crane to test remote control operation, (TM 9-2320-364-10).

• Stow remote control box, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

18-20 

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine ON (running), (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

End of boom at working level,

(TM 9-2320-364-10)

Hoist cable payed out, (TM 9-2320-364-10)

Crane hook block and clevis removed,

(Para 18-8)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Gloves, Heavy Duty (Item 29, Appendix G)

18-5. CRANE HOIST CABLE REPLACEMENT.

a. Removal.

Wear heavy gloves when handling crane cable. Never let cable run through hands; frayed

cables can cut.

NOTE

Use punch on wedge inside retainer.

(1) Knock out and remove wedge (1).

(2) Straighten cable (2) and remove from retainer (3) of hoist drum (4).
TM 9-2320-364-20-5

 18-21

b. Installation.

Wear heavy gloves when handling crane cable. Never let cable run through hands; frayed cable

can cut.

(1) Lay cable (2) out on level surface and remove loops.

(2) With the aid of an assistant, feed cable (2) over sheave pulley (5) and thread through hoist drum (4) from

inside to outside of reel.

(3) Feed cable (2) up through retainer (3) and loop back around.

(4) Position wedge (1) inside looped cable (2). Tighten cable around wedge until 1 in. (25.4 mm) of cable

extends out of retainer (3).

c. Follow-On Maintenance:

• Install hook block and clevis, (Para 18-8).

• Reel in hoist cable, (TM 9-2320-364-10).

• Load test crane, (TM 9-2320-364-34).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

18-22 

Material/Parts

Cloth, Cleaning (Item 34, Appendix C)

Oil, Hydraulic (Item 50, Appendix C)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Crane hoist cable payed out approximately

1 ft (0.3 m), (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Pan, Drain 4 gal (Item 47, Appendix G)

Soldering Kit, Torch

(Item 64, Appendix G)

Vise, Machinist’s (Item 75, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0 to 237 N.

m])

(Item 95, Appendix G)

18-6. RETAINER BAR/ROLLER REPLACEMENT.

Material/Parts - Continued

Sealing Compound (Item 72, Appendix C)

Lockwasher (4) (Item 154, Appendix F)

Lockwasher (4) (Item 168, Appendix F)

Lockwasher (8) (Item 171, Appendix F)

Lockwasher (2) (Item 173, Appendix F)

Packing, Preformed (2) (Item 229, Appendix F)

Packing, Preformed (Item 248, Appendix F)
TM 9-2320-364-20-5

 18-23

a. Removal.

The crane hydraulic system operates at oil pressures up to 3,100 psi (21,375 kPa). Never

disconnect any hydraulic line or fitting without first dropping the pressure to zero. Failure to

comply may result in serious injury or death to personnel.

NOTE

• Tag and mark hoses prior to removal.

• Cap and plug hoses and fittings after removal.

(1) Position drain pan under two hoses (1) and hose (2).

(2) Disconnect two hoses (1) and hose (2) and remove two preformed packings (3) and preformed packing (4)

from two fittings (5) and elbow (6). Discard preformed packings.

(3) Remove four screws (7), lockwashers (8), hoist motor valve (9) and two preformed packings (10) from

motor (11). Discard lockwashers and preformed packings.
TM 9-2320-364-20-5

18-24 

18-6. RETAINER BAR/ROLLER REPLACEMENT (CONT).

(4) Remove four nuts (12), lockwashers (13),

screws (14) and bracket assembly (15) from

plates (16) and (17). Discard lockwashers.

(5) Remove four screws (18), lockwashers (19) and washers (20) from bar assembly (21) and plates (16) and

(17). Discard lockwashers.

(6) Remove two screws (22), lockwashers (23), washer (24), sensor bracket (25) and sensor (26) from

plate (16). Discard lockwashers.

(7) Remove four screws (27), lockwashers (28), bar assembly (21) and plates (16) and (17) from hoist

assembly (29). Discard lockwashers.
TM 9-2320-364-20-5

 18-25

(8) Remove two screws (30) and wear pad (31)

from bracket assembly (15).

(9) Remove two screws (32), lockwashers (33),

weld pin (34), four thrust washers (35) and

two roller assemblies (36) from bracket

assembly (15). Discard lockwashers.

Do not inhale fumes; could cause

severe injury or death.

NOTE

It will be necessary to heat the

screw with a propane torch to

remove the screw.

(10) Remove hex socket screw (37) from bar

assembly (21).

b. Installation.

Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors,

and are harmful to skin and clothing. To avoid injury or death, keep away from open fire

and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or

clothing, wash immediately with soap and water.

(1) Coat hex socket screw (37) with sealing compound.

(2) Install hex socket screw (37) in bar assembly (21). Torque screw to 15 lb-ft (20 N.

m).

(3) Install two roller assemblies (36), four thrust washers (35) and weld pin (34) in bracket assembly (15).

(4) Coat two screws (32) with sealing compound.

(5) Install two lockwashers (33) and screws (32) in bracket assembly (15). Torque screw to 12 lb-ft (20 N.

m).

(6) Coat two screws (30) with sealing compound.

(7) Install wear pad (31) on bracket assembly (15) with two screws (30).
TM 9-2320-364-20-5

18-26 

18-6. RETAINER BAR/ROLLER REPLACEMENT (CONT).

Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and

are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use

in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing,

wash immediately with soap and water.

(8) Coat four screws (27) with sealing compound.

(9) Position plates (16) and (17) with four lockwashers (28) and screws (27) on hoist assembly (29).

(10) Install sensor (26) and sensor bracket (25) to plate (16) with two lockwashers (23), washers (24) and

screws (22). Tighten screws to 16 lb-ft (22 N.

m).

(11) Coat four screws (18) with sealing compound.

(12) Position bar assembly (21) on plates (16) and (17) with four lockwashers (19), washers (20) and

screws (18).

(13) Tighten four screws (27) on plates (16) and (17) to 68 lb-ft (91 N.

m).

(14) Adjust gap between bar assembly (21) and drum flange (38) to .06 in. (1.52 mm). Tighten four screws

(18) to 30 lb-ft (41 N.

m).
TM 9-2320-364-20-5

 18-27

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(15) Coat four screws (14) with sealing

compound.

(16) Install bracket assembly (15) on plates (16) and (17) with four lockwashers (13), screws (14) and nuts (12).

(17) Apply hydraulic oil to two preformed packings (10).

(18) Install two preformed packings (10) and position hoist motor valve (9) on motor (11).

(19) Apply sealing compound on threads of four screws (7).

(20) Install four lockwashers (8) and screws (7) on hoist motor valve (9). Tighten screws to 15 to 17 lb-ft 

(20 to 23 N.

m).

(21) Apply hydraulic oil to two preformed packings (3) and preformed packing (4).

(22) Install two preformed packings (3) and

preformed packing (4) on two fittings (5)

and elbow (6).

NOTE

Install hoses as noted prior to

removal.

(23) Install two hoses (1) and hose (2) on two

fittings (5) and elbow (6).

c. Follow-On Maintenance:

• Fill hydraulic reservoir, 

(Para 2-9, Lubrication Table 2-3).

• Check operation, (TM 9-2320-364-10).

• Check for oil leaks, (TM 9-2320-364-10).

• Load test crane, (TM 9-2320-364-34).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

18-28 

Materials/Parts

Adhesive, Retaining (Item 13, Appendix C)

Sealing Compound (Item 77, Appendix C)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Torque (0-60 N.

m)

(Item 98, Appendix G)

18-7. CRANE ANGLE INDICATOR REPLACEMENT.

a. Removal.

NOTE

Both angle indicators are removed the same way.

(1) Remove cap plug (1) from pointer (2).

(2) Remove screw (3) and pointer (2) from crane frame (4).

(3) Remove nut (5), two washers (6) and screw (3) from bearing (7).

NOTE

Perform Step (4) if bearing is damaged.

(4) Remove bearing (7) from pointer (2).
TM 9-2320-364-20-5

 18-29

b. Installation.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and water.

NOTE

• Perform Step (1) and (2) if

bearing was removed.

• Remove any excess adhesive

from outer surfaces of

bearing.

(1) Apply adhesive between surfaces of 

bearing (7) and pointer (2).

(2) Install bearing (7) in pointer (2).

NOTE

Ensure pointer rotates freely after

installed.

(3) Install screw (3), two washers (6) and nut (5)

in bearing (7).

(4) Apply sealing compound to exposed threads

on end of screw (3).

(5) Install pointer (2) with screw (3) on 

crane (4). Tighten screw to 108 lb-in 

(12 N.

m).

(6) Install cap plug (1) on pointer (2).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

18-30 

Materials/Parts

Grease (Item 42, Appendix C)

Oil, Lubricating (Item 54, Appendix C)

Solvent, Drycleaning (Item 87, Appendix C)

Nut, Lock (Item 129, Appendix F)

Lockwasher (Item 200, Appendix F)

Pins, Cotter (12) (Item 275, Appendix F)

Washer, Key (Item 350, Appendix F)

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Dissassembly d. Assembly f. Follow-on Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Hook block lowered to ground,

(TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Gloves, Heavy Duty (Item 29, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

Pliers, Retaining Ring (Item 49, Appendix G)

Wrench, Combination 1-1/8 in.

(Item 79, Appendix G)

Wrench, Combination 1-1/2 in.

(Item 83, Appendix G)

Wrench, Torque (0-175 lb-ft [0-237 N.

m])

(Item 95, Appendix G)

18-8. CRANE HOOK BLOCK, HOOK AND CLEVIS REPAIR.

a. Removal.

Wire rope can become frayed or

contain broken wires. Wear heavy

leather-palmed work gloves when

handling wire rope. Never let

moving wire rope slide through

hands, frayed or broken wires can

cause injury to personnel.

(1) Remove cotter pin (1), castle nut (2), two

washers (3) and screw (4) from open wedge

socket clevis (5). Discard cotter pin.

(2) Remove open wedge socket clevis (5) from

fly section (6).
TM 9-2320-364-20-5

 18-31

NOTE

Use punch on wedge inside

clevis.

(3) Knock out and remove wedge (7) from open

wedge socket clevis (5).

(4) Straighten and remove cable (8) from hook

block (9).

b. Disassembly.

(1) Remove screw (1), lockwasher (2),

washer (3) and lock pin (4) from hook

block (5). Discard lockwasher.

(2) Remove bushing (6) from lock pin (4).

(3) Remove 10 cotter pins (7) and five pins (8)

from hook block (5). Discard cotter pins.
TM 9-2320-364-20-5

18-32 

18-8. CRANE HOOK BLOCK, HOOK AND CLEVIS REPAIR (CONT).

(4) Bend down tines of key washer (9).

(5) Hold pin (10) and remove nut (11), key

washer (9), sheave (12), pin (10) and

spacer (13) from hook block (5). Discard

key washer.

(6) Remove grease fitting (14) from pin (10).

Use care when removing bearings

from races. Bearings may fall

and damage to equipment may

result.

(7) Remove two tapered roller bearings (15)

from sheave (12).

Use care when removing 

retaining rings. Retaining rings 

are under spring tension and can

act as projectiles when released

and could cause severe eye injury.

NOTE

Perform Step (8) if bearing races

are damaged.

(8) Remove two bearing races (16) and retaining

rings (17) from sheave (12).

(9) Remove cotter pin (18) and castle nut (19)

from hook (20). Discard cotter pin.

(10) Remove washer (21) and shield (22) from

hook (20).

(11) Remove bearing (23) from shield (22).

(12) Remove hook (20) from hook block (5).
TM 9-2320-364-20-5

 18-33

Use care when removing springs.

Springs are under tension and 

can act as projectiles when 

released and could cause injury 

to personnel.

(13) Remove pin (24), locknut (25), screw (26),

spring (27) and latch (28) from hook (20).

Discard locknut.

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc).

Failure to comply may result in injury or death to personnel.

(1) Clean all metal parts with drycleaning solvent.

(2) Allow bearing to air dry, then coat with lubricating oil.

(3) Dry metal parts with compressed air.

(4) Inspect metal parts for breaks, cracks and sharp edges.

(5) Inspect bushing for cuts or nicks.

(6) Inspect bearing for loose rollers or cracked and broken races.

(7) Replace all damaged parts.
TM 9-2320-364-20-5

18-34 

18-8. CRANE HOOK BLOCK, HOOK AND CLEVIS REPAIR (CONT).

d. Assembly.

Use care when installing springs.

Springs are under tension and 

can act as projectiles when 

released and could cause injury 

to personnel.

NOTE

Legs of spring must be positioned

behind latch.

(1) Position spring (27) in latch (28).

(2) Install latch (28) on hook (20) with

screw (26), and locknut (25).

(3) Install pin (24) in hook (20).

(4) Apply grease to bearing (23) and install

bearing in shield (22).

NOTE

Ensure that bearing is installed

with cup facing up.

(5) Install hook (20) in hook block (5) with

shield (22), washer (21) and castle nut (19).

(6) Install cotter pin (18) in slot of castle

nut (19) and hook block (5).
TM 9-2320-364-20-5

 18-35

(7) Install grease fitting (14) in pin (10).

Use care when installing retaining

rings. Retaining rings are under

spring tension and can act as

projectiles when released and

could cause severe eye injury.

NOTE

Perform Step (8) if bearing races

were removed.

(8) If removed, install retaining ring (17) and

two bearing races (16) in sheave (12).

(9) Pack two roller bearings (15) with grease

and install bearings in sheave (12).

(10) Apply grease on spacer (13) and install

sheave (12) and bushing in hook block (5)

with pin (10), key washer (9) and nut (11).

(11) Install five pins (8) in hook block (5) with

10 cotter pins (7).

(12) Install bushing (6) in lock pin (4).

(13) Install lock pin (4) in hook block (5) with

washer (3), lockwasher (2) and screw (1).

Tighten screw to 135 lb-ft (183 N.

m).

(14) Tighten nut (11) on pin (10).

(15) Bend tabs of key washer (9) into slots on

nut (11).
TM 9-2320-364-20-5

18-36 

18-8. CRANE HOOK BLOCK, HOOK AND CLEVIS REPAIR (CONT).

e. Installation.

Wire rope can become frayed or

contain broken wires. Wear 

heavy leather-palmed work 

gloves when handling wire rope.

Never let moving wire rope slide

through hands, frayed or broken

wires can cause injury to 

personnel.

(1) Position cable (8) through hook block (9).

(2) Position cable (8) through hole in open

wedge socket clevis (5).

(3) Make loop in cable (8) and position free end

of cable through second hole in open wedge

socket clevis (5).

(4) Install wedge (7) in cable loop. Drive wedge

and cable loop into open wedge socket 

clevis (5).

NOTE

When installed properly, open

wedge socket clevis should rotate

freely on fly section.

(5) Install open wedge socket clevis (5) on fly

section (6) with screw (4), washer (3), castle

nut (2) and cotter pin (1).

f. Follow-On Maintenance:

• Lubricate hook block, (Para 2-9).

• Operate crane, (TM 9-2320-364-10).

• Load test crane, (TM 9-2320-364-34).

• Stow crane, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 18-37

Materials/Parts

Oil, Lubricating (Item 54, Appendix C)

Sealing Compound (Item 72, Appendix C)

Solvent, Drycleaning (Item 87, Appendix C)

Lockwasher (4) (Item 178, Appendix F)

Packing, Preformed (Item 225, Appendix F)

Packing, Preformed (Item 228, Appendix F)

Packing, Preformed (Item 256, Appendix F)

Packing, Preformed (Item 263, Appendix F)

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

18-9. AUXILIARY HAND PUMP REPAIR.

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

Pan, Drain (Item 47, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Torque (0-60 N.

m)

(Item 98, Appendix G)

a. Removal.

NOTE

• Tag and mark hydraulic hoses

prior to removal.

• Position drain pan under

hoses.

• Cap and plug hoses and

fittings after removal.

(1) Remove hose (1) and preformed packing (3)

from elbow (2). Discard preformed packing (3).

(2) Remove hose (4) and preformed packing (6)

from elbow (5). Discard preformed packing (6).

(3) Remove four screws (7), lockwashers (8) and

pump (9) from mount (10). Discard 

lockwashers.
TM 9-2320-364-20-5

18-38 

18-9. AUXILIARY HAND PUMP REPAIR (CONT).

b. Disassembly.

(1) Remove elbows (1) and (2) and preformed

packings (3) and (4). Discard preformed

packings.

(2) Remove two clips (5) and pin (6).

(3) Remove two clips (7), pin (8) and handle

socket (9).

(4) Remove two clips (10), pin (11) and 

link (12) from pump (13).

(5) Remove piston (14) from pump (13).

(6) Remove seal (15) and two wipers (16) from

pump (13).

(7) Remove cap (17), spring (18), check

ball (19), spring (20) and check ball (21)

from pump (13).
TM 9-2320-364-20-5

 18-39

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc).

Failure to comply may result in injury or death to personnel.

(1) Clean all metal parts with drycleaning solvent.

(2) Dry metal parts with compressed air.

(3) Inspect metal parts for breaks, cracks and sharp edges.

(4) Replace all damaged parts.

d. Assembly.

(1) Install check ball (21), spring (20), check

ball (19), spring (18) and cap (17) in

pump (13).

(2) Install two wipers (16) and seal (15) in 

pump (13).

(3) Install piston (14) in pump (13).
TM 9-2320-364-20-5

18-40 

18-9. AUXILIARY HAND PUMP REPAIR (CONT).

(4) Install link (12) on pump (13) with pin (11)

and two clips (10).

(5) Install handle socket (9) in pump (13) with

pin (8) and two clips (7).

(6) Install pin (6) and two clips (5) in 

pump (13).

(7) Coat preformed packings (3) and (4) with

oil.

(8) Install preformed packings (3) and (4) on

elbows (1) and (2).

(9) Install elbows (1) and (2) in pump (13).

e. Installation.

(1) Install pump (9) on mount (10) with four

lockwashers (8) and screws (7). Tighten

screws to 17 lb-ft (23 N.

m).

(2) Install preformed packing (6) and hose (4) to

elbow (5).

(3) Install preformed packing (3) and hose (1) to

elbow (2).

f. Follow-On Maintenance:

• Check hydraulic fluid level,

(Para 2-9, Lubrication Table 2-3).

• Operate pump and check for leaks,

(TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 18-41

Material/Parts

Oil, Lubricating (Item 54, Appendix C)

Sealing Compound (Item 73, Appendix C)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

Pan, Drain (Item 47, Appendix G)

18-10. CRANE ACCUMULATOR REPLACEMENT.

Material/Parts - Continued

Tags, Identification (Item 88, Appendix C)

Locknut (2) (Item 133, Appendix F)

Packing, Preformed (Item 228, Appendix F)

a. Removal.

The crane hydraulic system operates at oil pressures up to 3100 psi (21,365 kPa). Never

disconnect any hydraulic line or fitting without first dropping the pressure to zero. Failure to

comply may result in serious injury or death to personnel.

NOTE

• Tag and mark all hoses and tubes, and mark position of elbow before removal.

• Position drain pan under accumulator.

• Cap and plug hoses and fittings after removal.

(1) Remove hose (1) from elbow (2).

(2) Remove and discard preformed packing (3) from elbow (2).
TM 9-2320-364-20-5

18-42 

18-10. CRANE ACCUMULATOR REPLACEMENT (CONT).

(3) Remove two locknuts (4), clamp (5), accumulator (6) and spacer (7) from right bracket (8). Discard

locknuts.

(4) Remove elbow (2) from accumulator (6).

b. Installation.

Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and

are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use

in a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing,

wash immediately with soap and water.

(1) Apply sealing compound to threads of elbow (2) and install on accumulator (7).

Do not over-tighten clamp during installation. Accumulator is filled with compressed gas, and a

change in pressure could cause crane to malfunction. Failure to complay may result in injury or

death to personnel.

(2) Install accumulator (6) and spacer (7) on right bracket (8) with clamp (5) and two locknuts (4).

(3) Apply oil to preformed packing (3).

(4) Install preformed packing (3) on elbow (2).

(5) Install hose (1) on elbow (2).
TM 9-2320-364-20-5

 18-43

c. Follow-On Maintenance:

• Start engine, (TM 9-2320-364-10).

• Place selector switch in Crane mode and check for leaks, (TM 9-2320-364-10).

• Load test crane, (TM 9-2320–364-34).

• Shut OFF engine, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

18-44 

Materials/Parts

Hydraulic Oil (Item 50, Appendix C)

This task covers:

a. Hydraulic Hoses and Tubes Replacement d. Type 3 Clamp Replacement

b. Type 1 Clamp Replacement e. Follow-On Maintenance

c. Type 2 Clamp Replacement

INITIAL SETUP

Equipment Condition

Crane in operating position and supported by

suitable lifting device, (TM 9-2320-364-10)

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

18-11. CRANE HYDRAULIC HOSES, TUBES AND FITTINGS REPLACEMENT.

Materials/Parts - Continued

Tags, Identification (Item 88, Appendix C)

Packing, Preformed (Item 226, Appendix F)

The crane hydraulic system operates at oil pressures up to 3100 psi (21,375 kPa). Never

disconnect any hydraulic line or fitting without first dropping the pressure to zero. Failure to

comply may result in serious injury or death to personnel.

NOTE

• Subparagraphs (a) through (d) show all typical connections and clamps used on the crane.

• This procedure is used to show the location of hoses, tubes and fittings used on the crane.

It is for reference only. It will never be necessary to remove all hydraulic hoses at one time.

• Tag and mark all hoses and tubes prior to removal.

• Cap and plug hoses, tubes and fittings after removal.

a. Hydraulic Hoses and Tubes Replacement.

NOTE

Some hoses and tubes will not

have preformed packings.

(1) Removal. Loosen fitting (1). Remove

preformed packing (2) and hose (3) from

elbow (4). Discard preformed packing.

(2) Installation.

(a) Apply hydraulic oil to preformed

packing (2).

(b) Install preformed packing (2) in

fitting (1). Connect fitting and hose

(3) to elbow (4).
TM 9-2320-364-20-5

 18-45

b. Type 1 Clamp Replacement.

(1) Removal. Remove screw (1), spacer (2) and

clamps (3).

(2) Installation. Install clamps (3) and spacer

(2) with screw (1).

c. Type 2 Clamp Replacement.

(1) Removal. Remove two screws (1), spacers

(2) and clamps (3).

(2) Installation. Install clamps (3) and spacers

(2) with two screws (1).

d. Type 3 Clamp Replacement.

NOTE

Do not remove screw. Screw

holding clamp also holds hoist

pivot pin in place.

(1) Removal. Remove nut (1) and clamp (2)

from screw (3).

(2) Installation. Install clamp (2) on screw (3)

with nut (1).
TM 9-2320-364-20-5

18-46 

18-11. CRANE HYDRAULIC HOSES, TUBES AND FITTINGS REPLACEMENT (CONT).

From To

Hose or Tube Component Figure Component Figure

A Elbow (1) 18-1 45 Degree Elbow (2) 18-2

B 45 Degree Elbow (3) 18-1 45 Degree Elbow (4) 18-2

C Valve (5) 18-1 Tube End (6) 18-1

D Valve (5) 18-1 Tube End (7) 18-1

E Tube End (6) 18-1 Tube End (8) 18-1

F Tube End (6) 18-1 Elbow (9) 18-1

G Elbow (7) 18-1 Tube End (10) 18-2

H Tube End (8) 18-1 Tube End (11) 18-1

I Tube End (11) 18-1 Tube End (12) 18-1

J Tube End (12) 18-1 Tube End (13) 18-1

K Tube End (13) 18-1 Elbow (14) 18-8

L Valve (15) 18-1 Fitting (16) 18-1

Figure 18-1. Hoist Hoses and Tubes (Left Side)
TM 9-2320-364-20-5

 18-47

From To

Hose or Tube Component Figure Component Figure

M Check valve (17) 18-2 Tube End (18) 18-2

N Tube End (18) 18-2 Tube End (19) 18-2

O Tube End (19) 18-2 Tube End (20) 18-2

P Tube End (20) 18-2 Tube End (21) 18-2

Q Tube End (21) 18-2 Tube Weldment (22) 18-16

R Tube End (10) 18-2 Tube End (23) 18-2

S Tube End (23) 18-2 Tube End (24) 18-2

T Tube End (24) 18-2 Tube End (25) 18-2

U Tube End (25) 18-2 Hoist Elbow (26) 18-8

V Valve (27) 18-2 Fitting (28) 18-2

Figure 18-2. Hoist Hoses and Tubes (Right Side)
TM 9-2320-364-20-5

18-48 

18-11. CRANE HYDRAULIC HOSES, TUBES AND FITTINGS REPLACEMENT (CONT).

From To

Hose or Tube Component Figure Component Figure

W Fitting (29) 18-3 Elbow (30) 18-4

X Elbow (31) 18-3 Tee (32) 18-4

Y Tee (33) 18-3 45 Degree Elbow (34) 18-4

Z Tee (33) 18-3 Tube End (35) 18-3

AA Tube End (35) 18-3 Tube End (36) 18-3

AB Tube End (36) 18-3 Telescope Elbow (37) 18-8

Figure 18-3. Telescope Cylinders Hoses and Tubes
TM 9-2320-364-20-5

 18-49

From To

Hose or Tube Component Figure Component Figure

AC Tee (32) 18-4 Tube End (38) 18-4

AD Tube End (38) 18-4 Tube End (38) 18-4

AE Tube End (38) 18-4 Telescoping Elbow (40) 18-8

Figure 18-4. Telescope Cylinders Hoses and Tubes
TM 9-2320-364-20-5

18-50 

18-11. CRANE HYDRAULIC HOSES, TUBES AND FITTINGS REPLACEMENT (CONT).

From To

Hose or Tube Component Figure Component Figure

AF Valve (41) 18-5 Valve (42) 18-5

AG Valve (41) 18-5 Valve (42) 18-5

AH Valve (41) 18-5 Valve (42) 18-5

AI Fitting (28) 18-5 Boom Elbow (43) 18-8

AJ Fitting (16) 18-5 Boom Elbow (44) 18-8

Figure 18-5. Lift Cylinders Hoses and Tubes
TM 9-2320-364-20-5

 18-51

From To

Hose or Tube Component Figure Component Figure

AK Elbow (45) 18-6 Mast Elbow (46) 18-10

AL Elbow (47) 18-6 Mast Elbow (48) 18-10

Figure 18-6. Mast Erection Cylinders Hoses and Tubes
TM 9-2320-364-20-5

18-52 

18-11. CRANE HYDRAULIC HOSES, TUBES AND FITTINGS REPLACEMENT (CONT).

From To

Hose or Tube Component Figure Component Figure

AM Elbow (49) 18-7 Elbow (50) 18-7

AN Fitting (51) 18-7 Swing Elbow (52) 18-8

AO Fitting (53) 18-7 Swing Elbow (54) 18-8

Figure 18-7. Swing Drive Hoses and Tubes
TM 9-2320-364-20-5

 18-53

From To

Hose or Tube Component Figure Component Figure

AP Elbow (55) 18-8 Fitting (56) 18-12

AQ Fitting (57) 18-8 Tee Weldment (58) 18-16

AR Fitting (59) 18-8 Elbow (60) 18-14

AS Fitting (61) 18-8 45 Degree Elbow (62) 18-9

AT Fitting (63) 18-8 Elbow (64) 18-10

AU Fitting (65) 18-8 Capped 18-8

AV Fitting (58) 18-16 Fitting (70) 18-16

Figure 18-8. Four Function Control Valve
TM 9-2320-364-20-5

18-54 

18-11. CRANE HYDRAULIC HOSES, TUBES AND FITTINGS REPLACEMENT (CONT).

From To

Hose or Tube Component Figure Component Figure

AS Fitting (61) 18-8 45 Degree Elbow (62) 18-9

Figure 18-9. Accumulator
TM 9-2320-364-20-5

 18-55

From To

Hose or Tube Component Figure Component Figure

AW Elbow (68) 18-10 Fitting (69) 18-12

AX Elbow (70) 18-10 Tee Weldment (58) 18-8,

18-16

AY Elbow (71) 18-10 Tee (72) 18-17

AZ Elbow (73) 18-10 Tee (74) 18-17

BA Elbow (75) 18-10 Tee (76) 18-17

BB Elbow (77) 18-10 Tee (78) 18-17

Figure 18-10. Three Function Control Valve
TM 9-2320-364-20-5

18-56 

18-11. CRANE HYDRAULIC HOSES, TUBES AND FITTINGS REPLACEMENT (CONT).

From To

Hose or Tube Component Figure Component Figure

BC Elbow (79) 18-10 Elbow (80) 18-16

BD Fitting (81) 18-10 Fitting (82) 18-12

Figure 18-11. Manual Override Valve
TM 9-2320-364-20-5

 18-57

From To

Hose or Tube Component Figure Component Figure

BE Tube Weldment (83) 18-13 Fitting (84) 18-14

BF Elbow (85) 18-13 Tube Weldment (86) 18-16

BG Elbow (87) 18-13 Elbow (88) 18-13

Figure 18-12. Manual Override Solenoid
TM 9-2320-364-20-5

18-58 

18-11. CRANE HYDRAULIC HOSES, TUBES AND FITTINGS REPLACEMENT (CONT).

From To

Hose or Tube Component Figure Component Figure

BH Elbow (89) 18-13 Fitting (90) 18-16

Figure 18-13. Hydraulic Hand Pump Hoses and Tubes
TM 9-2320-364-20-5

 18-59

From To

Hose or Tube Component Figure Component Figure

BI Fitting (91) 18-14 Tee Weldment (92) 18-16

BJ Fitting (93) 18-14 Tee (72) 18-17

BK Fitting (94) 18-14 Tee (74) 18-17

BL Fitting (95) 18-14 Tee (78) 18-17

BM Fitting (96) 18-14 Tee (76) 18-17

Figure 18-14. Two Function Control Valve
TM 9-2320-364-20-5

18-60 

18-11. CRANE HYDRAULIC HOSES, TUBES AND FITTINGS REPLACEMENT (CONT).

From To

Hose or Tube Component Figure Component Figure

BN Elbow (98) 18-15 Tee (72) 18-17

BO Elbow (99) 18-15 Tee (74) 18-17

BP Elbow (100) 18-15 Tee (78) 18-17

BQ Elbow (101) 18-15 Tee (76) 18-17

Figure 18-15. Outrigger Cylinders
TM 9-2320-364-20-5

 18-61

From To

Hose or Tube Component Figure Component Figure

BR Tee Weldment (58) 18-16 Tee Weldment (92) 18-16

BS Tee Weldment (92) 18-16 Fitting (101) 18-16

BT Fitting (101) 18-16 Hydraulic Filter

BU Fitting (102) 18-16 Hydraulic Distribution Manifold

BV Fitting (90) 18-16 Hydraulic Reservoir

BW Fitting (67) 18-16 Hydraulic Distribution Manifold

Figure 18-16. Main Hydraulic Hoses and Tubes
TM 9-2320-364-20-5

18-62 

18-11. CRANE HYDRAULIC HOSES, TUBES AND FITTINGS REPLACEMENT (CONT).

From

Hose or Tube Figure Component Figure

To

Hose or Tube Figure

AY 18-10 Tee (72) 18-17 BL 18-15

AZ 18-10 Tee (74) 18-17 BM 18-15

BA 18-10 Tee (78) 18-17 BN 18-15

BB 18-10 Tee (76) 18-17 BO 18-15

Figure 18-17. Under Base Connections

e. Follow-On Maintenance:

• Check oil level, (TM 9-2320-364-10).

• Remove lifting device, (TM 9-2320-364-10).

• Return crane to transport position, (TM 9-2320-364-10).

• Load test crane, (TM 9-2320-364-34-2).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 18-63

Materials/Parts

Tags, Identification (Item 88, Appendix C)

Locknut (12) (Item 92, Appendix F)

Lockwasher (2) (Item 165, Appendix F)

Packing, Preformed (3) (Item 251, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

LHS fully extended, (TM 9-2320-364-10)

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Winch cable removed, (Para 18-17)

Crane storage box removed (trucks equipped

with crane only), (Para 17-55)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

Pan, Drain (Item 47, Appendix G)

Socket Set, 3/4 in. (Item 62, Appendix G)

Wrench, Combination 1-1/8 in.

(Item 79, Appendix G)

Wrench, Combination 1-1/4 in.

(Item 80, Appendix G)

Wrench, Combination 1-3/8 in.

(Item 82, Appendix G)

Wrench, Combination 1-5/8 in.

(Item 84, Appendix G)

Wrench, Torque (0 to 300 lb-ft [0-407 N.

m])

(Item 96, Appendix G)

Lifting Device, Minimum Capacity 645 lb

(293 kg)

18-12. SELF-RECOVERY WINCH (SRW) REPLACEMENT.

a. Removal.

NOTE

• Tag and mark connectors, hoses and tubes upon removal.

• Cap and plugs hoses and tubes upon removal.

(1) Loosen screw (1) and disconnect MC121 connector (2) from control valve (3).

(2) Loosen screw (4) and disconnect MC122 connector (5) from control valve (3).

(3) Loosen screw (6) and disconnect MC123 connector (7) from control valve (3).
TM 9-2320-364-20-5

18-64 

18-12. SELF-RECOVERY WINCH (SRW) REPLACEMENT (CONT).

(4) Position drain pan under hydraulic tubes (8)

and (9).

(5) Loosen nuts (10) and (11) and remove

hydraulic tube (8) from fittings (12)

and (13).

(6) Loosen nuts (14) and (15) and remove

hydraulic tube (9) from fittings (16)

and (17).

(7) Remove hose (18) and preformed

packing (19) from elbow (20) on control

valve (3). Discard preformed packing.

(8) Remove hose (21) and preformed

packing (22) from elbow (23) on control

valve (3). Discard preformed packing.

(9) Remove hose (24) and preformed

packing (25) from fitting (26) on control

valve (3). Discard preformed packing.

(10) Remove two screws (27) lockwashers (28),

washers (29) and bracket (30) from

winch (31). Discard lockwashers.
TM 9-2320-364-20-5

 18-65

Self-recovery winch weighs 645

lbs (292 kg). Attach suitable 

lifting device to prevent possible

injury to personnel.

(11) Attach lifting device to self-recovery

winch (31).

(12) With the aid of an assistant, remove eight

locknuts (32) and screws (33) from selfrecovery winch mounting bracket (34).

Discard locknuts.

(13) With the aid of an assistant, remove four

locknuts (35) and screws (36) from selfrecovery winch mounting bracket (34).

Discard locknuts.

(14) With the aid of an assistant, remove selfrecovery winch (31) from frame (37).

b. Installation.

Self-recovery winch weighs 645 lbs (292 kg). Attach suitable lifting device to prevent

possible injury to personnel.

NOTE

Remove caps and plugs from hoses and tubes prior to installation.

(1) Attach lifting device to self-recovery winch (31).

(2) With the aid of an assistant, position self-recovery winch (31) on frame (37) with eight screws (33) and

locknuts (32) in self-recovery winch mounting bracket (34).

(3) With the aid of an assistant, position four screws (36) and locknuts (35) in self-recovery winch mounting

bracket (34).

(4) With the aid of an assistant, tighten eight screws (33), locknuts (32), four screws (36) and locknuts (35) to

210 lb-ft (285 N.

m)

(5) Remove lifting device from self-recovery winch (31).
TM 9-2320-364-20-5

18-66 

18-12. SELF-RECOVERY WINCH (SRW) REPLACEMENT (CONT).

(6) Install bracket (30) on winch (31) with two

washers (29), lockwashers (28) and

screws (27).

(7) Install preformed packing (25) and hose (24)

on fitting (26).

(8) Install preformed packing (22) and hose (21)

on elbow (23).

(9) Install preformed packing (19) and hose (18)

on elbow (20).

(10) Install hydraulic tube (9) on fittings (16)

and (17) and tighten nuts (14) and (15).

(11) Install hydraulic tube (8) on fittings (12)

and (13) and tighten nuts (10) and (11).
TM 9-2320-364-20-5

 18-67

(12) Connect MC123 (7), MC122 (5) and

MC121 (2) connectors on control valve (3).

(13) Tighten screws (1), (4), and (6).

c. Follow-On Maintenance:

• Connect batteries, (Para 7-87).

• Start engine, (TM 9-2320-364-10).

• Check for oil leaks, (TM 9-2320-364-10).

• Check hydraulic oil level, (Para 2-9, Lubrication Table 2-3).

• Install crane stowage box (trucks equipped with crane only), (Para 17-55).

• Install winch cable, (Para 18-17).

• LHS in transit position, (TM 9-2320-364-10).

• Shut OFF engine, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

18-68 

Material/Parts

Solvent, Drycleaning (Item 87, Appendix C)

Locknut (4) (Item 123, Appendix F)

Pin, Cotter (2) (Item 272, Appendix F)

This task covers:

a. Removal. c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0-237 N.

m])

(Item 95, Appendix G)

Wrench, Torque (0 to 60 N.

m)

(Item 98, Appendix G)

18-13. SELF-RECOVERY WINCH (SRW) FRONT TENSION GUIDE REPAIR.

a. Removal.

Front tension guide weighs 60 lbs

(27 kg). Use an assistant to

prevent possible injury to

personnel.

(1) With the aid of an assistant, remove four

locknuts (1) from screws (2) and (3).

Discard locknuts.

(2) With the aid of an assistant, support front

tension guide (4).

(3) With the aid of an assistant, remove 

screws (2) and (3) and front tension guide

assembly (4) from frame (5).
TM 9-2320-364-20-5

 18-69

b. Disassembly.

(1) Remove three grease fittings (1) from front

tension guide assembly (2).

(2) Remove two locknuts (3) and U-bolt (4)

from tension pivot assembly (5). Discard

locknuts.

(3) Remove two locknuts (6), U-bolt (7) and

spring (8) from front tension guide

assembly (2). Discard locknuts.

(4) Remove cotter pin (9) and washer (10) from

tension pivot assembly (5). Discard cotter

pin.

(5) Remove tension pivot assembly (5) from

tension plate assembly (11).

(6) Remove cotter pin (12), locknut (13)

screw (14) and bracket (15) from tension

pivot assembly (5). Discard locknut.

(7) Remove roller assembly (16) from tension

pivot assembly (5).
TM 9-2320-364-20-5

18-70 

18-13. SELF-RECOVERY WINCH (SRW) FRONT TENSION GUIDE REPAIR (CONT).

(8) Remove cotter pin (17), locknut (18),

screw (19), bracket (20), roller assembly (21)

and spacer (22) from tension plate

assembly (11). Discard locknut.

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc).

Failure to comply may result in injury to personnel.

(1) Clean parts with drycleaning solvent.

(2) Wipe parts with clean cloth.

(3) Dry parts with compressed air.

(4) Inspect parts for cracks, gouges and broken welds.

(5) Replace all damaged parts.
TM 9-2320-364-20-5

 18-71

d. Assembly.

(1) Install spacer (22), roller assembly (21),

bracket (20), cotter pin (17), screw (19) and

locknut (18) on tension plate assembly (11).

(2) Install roller assembly (16) and bracket (15)

on tension pivot assembly (5) with cotter

pin (12).

(3) Install bracket (15) on tension pivot

assembly (5) with screw (14) and

locknut (13).

(4) Install tension pivot assembly (5) and

washer (10) on tension plate assembly (11)

with cotter pin (9).

(5) Install spring (8) and U-bolt (7) on front

tension guide assembly (2) with two

locknuts (6). Tighten locknuts until three

threads show on U-bolt ends.

(6) Install spring (8) and U-bolt (4) on tension

pivot assembly (5) with two locknuts (3).

Tighten locknuts until three threads show on

U-bolt ends.
TM 9-2320-364-20-5

18-72 

18-13. SELF-RECOVERY WINCH (SRW) FRONT TENSION GUIDE REPAIR (CONT).

(7) Install three grease fittings (1) in front

tension guide assembly (2).

e. Installation.

Front tension guide weighs 60 lbs

(27 kg). Use an assistant to

prevent possible injury to

personnel.

(1) With the aid of an assistant, position front

tension guide assembly (4) on frame (5) 

with four screws (2) and (3).

(2) With the aid of an assistant, install four

locknuts (1) on screws (3) and (2).

f. Follow-On Maintenance:

• Lubricate self-recovery winch front tension guide, (Para 2-9).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 18-73

Material/Parts

Locknut (6) (Item 91, Appendix F)

Locknut (3) (Item 93, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set 3/4 in. Drive (Item 61, Appendix G)

18-14. SELF-RECOVERY WINCH (SRW) FRONT GUIDE REPLACEMENT.

a. Removal.

• Front guide assembly weighs

75 lbs (34 kg). Use an

assistant to prevent injury

to personnel.

• Leave top front screw 

installed in frame to prevent

spacer from falling. Failure

to comply may result in

injury to personnel.

(1) With the aid of an assistant, remove three

screws (1) and locknuts (2) from guide

assembly (3). Discard locknuts.

(2) With the aid of an assistant, remove six

locknuts (4), four screws (5), one screw (6)

and guide assembly (3) from frame (7).

Discard locknuts.

(3) Remove spacer (8) and remaining screw (6)

from frame (7).
TM 9-2320-364-20-5

18-74 

18-14. SELF-RECOVERY WINCH (SRW) FRONT GUIDE REPLACEMENT (CONT).

b. Installation.

• Front guide assembly weighs 

75 lbs (34 kg). Use an 

assistant to prevent injury

to personnel.

• Position top front screw in

frame to hold spacer in place.

Failure to comply may result

in injury to personnel.

(1) With the aid of an assistant, position one

screw (6) and spacer (8) on frame (7).

(2) With aid of assistant, install guide

assembly (3), four screws (5), one screw (6)

and six locknuts (4) on frame (7).

(3) Install three screws (1) and locknuts (2) on

guide assembly (3).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 18-75

Material/Parts

Cloth, Cleaning (Item 31, Appendix C)

Sealing Compound (Item 77, Appendix C)

This task covers:

a. Removal c. Cleaning/Inspection e. Follow-On Maintenance

b. Disassembly d. Assembly

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Torque (0 to 60 N.

m)

(Item 98, Appendix G)

18-15. SELF-RECOVERY WINCH (SRW) REAR TENSION GUIDE REPAIR.

Material/Parts - Continued

Solvent, Drycleaning (Item 87, Appendix C)

Locknut (4) (Item 92, Appendix F) (if equipped

with CHU)

Locknut (2) (Item 123, Appendix F)

Locknut (4) (Item 132, Appendix F)

Pin, Cotter (3) (Item 272, Appendix F)

a. Removal.

Rear tension guide weighs 50 lbs (23 kg). Use an assistant to prevent injury to personnel.

NOTE

• Perform Steps (1) through (3) for trucks not equipped with CHU.

• Perform Steps (4) and (5) for trucks equipped with CHU.

(1) With the aid of an assistant, remove four locknuts (1) from screws (2) and (3). Discard locknuts.

(2) With the aid of an assistant, support rear tension guide assembly (4).

(3) With the aid of an assistant, remove screws (2) and (3) and rear tension guide assembly (4) from frame (5).
TM 9-2320-364-20-5

18-76 

18-15. SELF-RECOVERY WINCH (SRW) REAR TENSION GUIDE REPAIR (CONT).

(4) With the aid of an assistant, remove four

screws (6) and rear tension guide assembly

(4) from adapter plate (7).

(5) Remove two screws (8), screws (9), four

locknuts (10) and adapter plate (7) from

frame (5). Discard locknuts.

6

7

8

9

10

5

4

7
TM 9-2320-364-20-5

 18-77

b. Disassembly.

NOTE

Note position of grease fittings

before removal.

(1) Remove three grease fittings (1) from rear

tension guide assembly (2).

(2) Remove cotter pin (3), locknut (4), screw

(5), bracket (6), roller assembly (7) and

spacer (8) from tension plate assembly (9).

Discard cotter pin and locknut.

(3) Remove two locknuts (10), U-bolt (11) and

spring (12) from rear tension guide

assembly (2). Discard locknuts.

(4) Remove two locknuts (13), U-bolt (14) and

spring (12) from tension pivot

assembly (15). Discard locknuts.

(5) Remove locknut (16) from screw (17).

Discard locknut.

(6) Remove cotter pin (18) and bracket (19)

from tension pivot assembly (15). Discard

cotter pin.

(7) Remove roller assembly (20) from tension

pivot assembly (15).
TM 9-2320-364-20-5

18-78 

18-15. SELF-RECOVERY WINCH (SRW) REAR TENSION GUIDE REPAIR (CONT).

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc).

Failure to comply may result in injury or death to personnel.

(1) Clean parts with drycleaning solvent.

(2) Wipe parts with clean cloth.

(3) Dry parts with compressed air.

(4) Inspect parts for cracks, gouges, and broken welds.

(5) Replace all damaged parts.

d. Assembly.

(1) Install roller assembly (20) and bracket (19)

on tension pivot assembly (15).

(2) Install cotter pin (18) in tension pivot

assembly (15).

(3) Install locknut (16) on screw (17).

(4) Install spring (12) and U-bolt (14) on 

tension pivot assembly (15) with two

locknuts (13). Tighten locknuts until three

threads show on U-bolt ends.

(5) Install spring (12) and U-bolt (11) on rear

tension guide assembly (2) with two

locknuts (10). Tighten locknuts until three

threads show on U-bolt ends.
TM 9-2320-364-20-5

 18-79

(6) Install spacer (8), roller assembly (7) and

bracket (6) on tension plate assembly (9).

(7) Install cotter pin (3) in tension plate

assembly (9).

(8) Install screw (5) in bracket (6) and tension

plate assembly (9) with locknut (4).

(9) Install three grease fittings (1) in front

tension guide assembly (2).

e. Installation.

Rear tension guide weighs 50 lbs

(23 kg). Use an assistant to 

prevent injury to personnel.

NOTE

• Perform Steps (1) and (2) for

trucks not equipped with

CHU.

• Perform Steps (3) through

(5) for trucks equipped with

CHU.

(1) With the aid of an assistant, install rear

tension guide assembly (4), screws (3) 

and (2) on frame (5).

(2) With the aid of an assistant, install four

locknuts (1) on screws (3) and (2).
TM 9-2320-364-20-5

18-80 

18-15. SELF-RECOVERY WINCH (SRW) REAR TENSION GUIDE REPAIR (CONT).

(3) With the aid of an assistant, install two

screws (8), screws (9), four locknuts (10)

and adapter plate (7) to frame (5).

Adhesives, solvents and sealing

compounds can burn easily, can

give off harmful vapors and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(4) Apply sealing compound to four screws (6).

Rear tension guide weighs 50 lbs

(23 kg). Use an assistant to 

prevent injury to personnel.

(5) With the aid of an assistant, install rear

tension guide assembly (4) and four screws

(6) on adapter plate (7).

f. Follow-On Maintenance:

• Lubricate self-recovery winch rear tension guide, (Para 2-9).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

6

7

8

9

10

5

4

7
TM 9-2320-364-20-5

 18-81

Material/Parts

Locknut (2) (Item 92, Appendix F)

Locknut (Item 100, Appendix F)

Lockwasher (2) (Item 165, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

18-16. SELF-RECOVERY WINCH (SRW) REAR GUIDE REPLACEMENT.

a. Removal.

(1) With the aid of an assistant, remove two screws (1) and locknuts (2) from rear guide (3). Discard locknuts.

(2) With the aid of an assistant, remove locknut (4), washer (5), screw (6) and washer (7) from rear guide (3).

Discard locknut.

Rear guide assembly weighs 65 lbs (30 kg). Use an assistant to prevent possible injury to

personnel.

(3) With the aid of an assistant, remove two screws (8), lockwashers (9) and rear guide (3) from frame (10).

Discard lockwasher.
TM 9-2320-364-20-5

18-82 

18-16. SELF-RECOVERY WINCH (SRW) REAR GUIDE REPLACEMENT (CONT).

b. Installation.

Rear guide assembly weighs 65

lbs (30 kg). Use an assistant to

prevent possible injury to

personnel.

(1) With the aid of an assistant, position 

rear guide (3) on frame (10) with two

lockwashers (9) and screws (8).

(2) With the aid of an assistant, position

washer (7), screw (6), washer (5) and 

locknut (4) on rear guide (3).

(3) With the aid of an assistant, position two

locknuts (2) and screws (1) on rear guide (3).

(4) With the aid of an assistant, tighten two

screws (8) on rear guide (3).

(5) With the aid of an assistant, tighten two

locknuts (2) and locknut (4) on rear

guide (3).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 18-83

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Self-recovery winch cable payed out,

(TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Gloves, Heavy Duty (2) (Item 29, Appendix G)

18-17. SELF-RECOVERY WINCH (SRW) CABLE REPLACEMENT.

a. Removal.

• Wire cable assembly can become frayed or contain broken wires. Wear heavy leatherpalmed work gloves when handling wire cable assembly. Frayed or broken wires can cause

injury to personnel.

• Never let moving wire cable assembly slide through hands, even when wearing gloves. A

broken wire could cut through glove and cause injury to personnel.

(1) Remove wedge (1) and cable end (2) from cable wedge pocket (3) in drum (4).

(2) With the aid of an assistant, route cable end (2) through slot in cable wedge pocket (3).
TM 9-2320-364-20-5

18-84 

18-17. SELF-RECOVERY WINCH (SRW) CABLE REPLACEMENT (CONT).

(3) Remove cable assembly (5) from front cable tensioner (6) and front cable guide (7).

b. Installation.

• Wire cable assembly can become frayed or contain broken wires. Wear heavy

leather-palmed work gloves when handling wire cable assembly. Frayed or broken cable

can and cause injury to personnel.

• Never let moving wire cable assembly slide through hands, even when wearing gloves. A

broken wire could cut through glove and cause injury to personnel.

(1) Route cable assembly (5) through front cable guide (7) and front cable tensioner (6).
TM 9-2320-364-20-5

 18-85

(2) With the aid of an assistant, route cable end

(2) through slot and pull cable end through

cable wedge pocket (3) in drum (4).

(3) With the aid of an assistant, loop cable

end (2) and position in cable wedge

pocket (3).

(4) With the aid of an assistant, position

wedge (1) in loop of cable end (2) and install

securely in cable wedge pocket (3).

c. Follow-On Maintenance:

• Wind cable in self-recovery winch, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

18-86 

Materials/Parts

Solvent, Drycleaning (Item 87, Appendix C)

Locknut (Item 131, Appendix F)

Pin, Cotter (2) (Item 274, Appendix F)

This task covers:

a. Disassembly c. Assembly

b. Cleaning/Inspection d. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Outrigger pads removed, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

18-18. OUTRIGGER PADS REPAIR.

a. Disassembly.

NOTE

Both outrigger pads are

disassembled the same way.

(1) Remove two cotter pins (1) and pins (2)

from outrigger pad (3). Discard cotter pins.

(2) Remove two rings (4) and chains (5) from

pins (2).
TM 9-2320-364-20-5

 18-87

(3) Remove two nuts (6), washers (7), cables (8) and washers (9) from crane frame (10).

b. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc).

Failure to comply may result in injury or death to personnel.

(1) Clean all metal parts with drycleaning solvent.

(2) Dry metal parts with cleaning cloth.

(3) Dry metal parts with compressed air.

(4) Inspect metal parts for breaks, cracks and sharp edges.

(5) Replace all damaged parts.
TM 9-2320-364-20-5

18-88 

18-18. OUTRIGGER PADS REPAIR (CONT).

c. Assembly.

(1) Install two washers (9), cables (8), washers (7) and nuts (6) on crane frame (10).

(2) Install two chains (5) and rings (4) on

pins (6).

(3) Install two pins (2) on outrigger (3) with

cotter pins (1).

d. Follow-On Maintenance:

• Install outrigger pads, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 19-1

CHAPTER 19

ACCESSORY ITEMS MAINTENANCE

Para Contents Page

19-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1

19-2 Reflector Replacement 19-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-3 Mirror Assembly Repair 19-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-4 Windshield Wiper Motor Replacement 19-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-5 Wiper Arm Replacement 19-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-6 Wiper Blade Replacement 19-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-7 Windshield Wiper Idler Shaft Replacement 19-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-8 Windshield Washer Reservoir and Bracket Repair 19-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-9 Beacon Bracket Replacement 19-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-10 Air Horn Replacement 19-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-11 Air Horn Valve Replacement 19-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-12 Heater Assembly Replacement 19-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-13 Heater Blower Motor Replacement 19-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-14 Heater Core Replacement 19-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-15 Heater Hoses and Fittings Replacement 19-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-16 Fresh Air Box Replacement 19-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-17 Heater Control Panel Repair 19-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-18 Heater Control Valve Replacement 19-63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-19 Heater/Defroster Tubing Replacement 19-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-20 Data Plate Replacement 19-76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-21 Weight Classification Sign Replacement 19-79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19-1. INTRODUCTION.

This chapter contains maintenance instructions for removing, replacing, installing and adjusting accessory item

components as authorized by the Maintenance Allocation Chart (MAC) at the Unit Maintenance level.
TM 9-2320-364-20-5

19-2 

Material/Parts

Locknut (2) (Item 106, Appendix F) (rear fender only)

Locknut (2) (Item 109, Appendix F) (mud flap only)

Locknut (4) (Item 110, Appendix F) (mud flap only)

This task covers:

a. Removal (Type 1) c. Installation (Type 2) e. Follow-On Maintenance

b. Removal (Type 2) d. Installation (Type 1)

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

19-2. REFLECTOR REPLACEMENT.

Material/Parts - Continued

Screw, Self Tapping (2) (Item 314, Appendix F)

(rear roller only)

Screw, Self Tapping (2) (Item 317, Appendix F)

(cab door only)

a. Removal (Type 1). Remove two screws (1), reflector housing (2) and reflector (3) from cab (4). Discard 

screws.
TM 9-2320-364-20-5

 19-3

b. Removal (Type 2).

(1) Remove four locknuts (5), retaining plate (6), four screws (7) and mounting plate (8) from mounting

bracket assembly (9). Discard locknuts.

(2) Remove two locknuts (10), screws (11), reflector housing (12) and reflector (13) from mounting plate (8).

c. Installation (Type 2).

(1) Install reflector housing (12) and reflector (13) on mounting plate (8) with two screws (11) and

locknuts (10).

(2) Install mounting plate (8) and retaining plate (6) on mounting bracket assembly (9) with four screws (7)

and locknuts (5).

d. Installation (Type 1). Install reflector (3) and reflector housing (2) on cab (4) with two screws (1).

e. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

19-4 

Material/Parts

Lockwasher (6) (Item 195, Appendix F)

This task covers:

a. Removal c. Assembly e. Follow-On Maintenance

b. Disassembly d. Installation

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

19-3. MIRROR ASSEMBLY REPAIR.

a. Removal.

NOTE

Left and right mirror assemblies are removed the same way.

(1) Remove three screws (1) from cab door (2).

Ensure mirror assembly is fully supported prior to Step (2) or mirror assembly may fall and

damage to parts may occur.

(2) Remove three screws (3) and mirror assembly (4) from cab door (2).
TM 9-2320-364-20-5

 19-5

b. Disassembly.

(1) Remove two nuts (1), lockwashers (2) and

screws (3) from clamps (4). Discard

lockwashers.

(2) Remove loop (5) and clamps (4) from

bracket assembly (6).

(3) Remove nut (7), lockwasher (8), screw (9),

two washers (10), mirror head (11) and

clamp (12) from loop (5). Discard

lockwashers.

(4) Remove two nuts (13), lockwashers (14),

screws (15), spacers (16) and

mirrorhead (17) from bracket assembly (6).

Discard lockwashers.

(5) Remove nut (18), washer (19), mirror

head (20) and lockwasher (21) from mirror

head (17). Discard lockwasher.

c. Assembly.

(1) Install mirror head (20) on mirror head (17)

with lockwasher (21), washer (19) and

nut (18).

(2) Install mirror head (17) on bracket

assembly (6) with two spacers (16),

screws (15), lockwashers (14) and nuts (13).

(3) Position clamp (12) on loop (5) and install

mirror head (11) with two washers (10),

screw (9), lockwasher (8) and nut (7).

(4) Position clamps (4) on bracket assembly (6)

and install loop (5) on clamps with two

screws (3), lockwashers (2) and nuts (1).
TM 9-2320-364-20-5

19-6 

19-3. MIRROR ASSEMBLY REPAIR (CONT).

d. Installation.

NOTE

Left and right mirror assemblies

are installed the same way.

(1) Position mirror assembly (4) and three

screws (3) on cab door (2).

(2) Position three screws (1) in cab door (2).

(3) Tighten screws (1) and (3).

e. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 19-7

Materials/Parts

Cable Ties (Item 81, Appendix C)

Sealing Compound (Item 73, Appendix C)

Gasket, Strip (Item 73, Appendix F)

Lockwasher (1) (Item 159, Appendix F)

Screw Washer Assembly (3) (Item 308, Appendix F)

Screw, Self-Tapping (4) (Item 314, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Instrument panel removed, (Para 7-13)

Heater access panel removed, (Para 17-4)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Torque (0 to 60 N.

m)

(Item 98, Appendix G)

19-4. WINDSHIELD WIPER MOTOR REPLACEMENT.

a. Removal.

NOTE

Remove cable ties as required.

(1) Remove four screws (1) and dash panel (2) from dash (3).

(2) Position dash panel (2) out of way.
TM 9-2320-364-20-5

19-8 

19-4. WINDSHIELD WIPER MOTOR REPLACEMENT (CONT).

(3) Remove gasket (4) from upper plenums (5). Discard gasket.

(4) Remove three screw washer assemblies (6) from left upper plenum (5). Discard screw washer assemblies.

(5) Remove screw (7), washer (8), lockwasher (9) and left upper plenum (5) from heater (10). Discard

lockwasher.

(6) Remove left defroster tubing (11) from

plenum (12).

(7) Position defroster tubing (11) out of the way.

11

12
TM 9-2320-364-20-5

 19-9

NOTE

Connector is removed by gently prying on lock tab and pulling connector apart.

(8) Disconnect MC5 connector (13) from windshield wiper motor connector (14).

(9) Remove four self-tapping screws (15) from windshield wiper motor mounting plate (16) and bracket (17).

Discard self-tapping screws.

NOTE

Conlinks are removed by prying

arms from crank assembly.

(10) Disconnect two conlinks (18) from

windshield wiper crank assembly (19).

(11) Remove windshield wiper motor (20) from

windshield wiper motor mounting

bracket (17).

b. Installation.

(1) Position windshield wiper motor (20) on

windshield wiper motor mounting

bracket (17).

NOTE

Left wiper arm is installed first.

(2) Connect two conlinks (18) on windshield

wiper crank assembly (19).
TM 9-2320-364-20-5

19-10 

19-4. WINDSHIELD WIPER MOTOR REPLACEMENT (CONT).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(3) Coat threads of four self-tapping screws (15)

with sealing compound.

(4) Install four self-tapping screws (15) on

windshield wiper motor mounting plate (16)

and bracket (17). Tighten screws 90 to 110

lb-in (10 to 12 N.

m).

NOTE

Install cable ties as required.

(5) Connect MC5 connector (13) on windshield

wiper motor connector (14).

(6) Install defroster tubing (11) on plenum (12).

11

12
TM 9-2320-364-20-5

 19-11

(7) Install left upper plenum (5) on heater (10)

with screw (7), washer (8) and lockwasher

(9).

(8) Install three screw washer assemblies (6) in

left upper plenum (5).

(9) Install gasket (4) on upper plenum (5).

(10) Install dash panel (2) on dash (3) with four

screws (1).

c. Follow-On Maintenance:

• Install heater access panel, (Para 17-4).

• Install instrument panel, (Para 7-13).

• Check wiper operation, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

4

9 8

6

5

10

7
TM 9-2320-364-20-5

19-12 

Material/Parts

Hardware, Mounting (Item 75, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Wiper arms in park position,

(TM 9-2320-364-10)

Wiper blade removed, (Para 19-6)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Torque (0 to 60 N.

m)

(Item 98, Appendix G)

19-5. WIPER ARM REPLACEMENT.

a. Removal.

(1) Remove nut (1) and lockwasher (2) from wiper arm (3). Discard lockwasher.

(2) Remove washer tube (4) from nozzle (5).

(3) Pull wiper arm (3) away from windshield (6) slightly and install socket in wiper arm (3).

(4) Remove wiper arm (3) from mounting stud (7).

(5) Remove socket from wiper arm (3).
TM 9-2320-364-20-5

 19-13

(6) Remove washer nozzle (8) from hose (9) and

wiper arm (3).

b. Installation.

(1) Install washer nozzle (8) on hose (9) and

wiper arm (3).

(2) Push wiper arm (3) upward slightly and

install socket in wiper arm.

NOTE

Wiper arm is installed parallel to

molding on windshield.

(3) Install wiper arm (3) on mounting stud (7).

(4) Install lockwasher (2) and nut (1) on wiper

arm (3). Tighten nut to 90 lb-in (10 N.

m).

(5) Remove socket from wiper arm (3).

(6) Install washer tube (4) on nozzle (5).

c. Follow-On Maintenance:

• Install wiper blade, (Para 19-6).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

19-14 

Material/Parts

Locknut (Item 181, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

19-6. WIPER BLADE REPLACEMENT.

a. Removal.

Do not run wiper arms when wiper blade is removed or damage to windshield and wiper arm

may occur.

(1) Remove locknut (1) and screw (2) from wiper arm (3). Discard locknut.

(2) Remove wiper blade (4) from wiper arm (3).

b. Installation.

(1) Install wiper blade (4) on wiper arm (3).

Do not over-tighten nut. Wiper arm must be able to pivot or damage may occur to parts.

(2) Install screw (2) and nut (1) on wiper arm (3).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 19-15

Material/Parts

Locknut (Item 140, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Wiper arm removed, (Para 19-5)

Instrument panel removed (left idler shaft only),

(Para 7-13)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0-237 N.

m])

(Item 95, Appendix G)

19-7. WINDSHIELD WIPER IDLER SHAFT REPLACEMENT.

a. Removal.

NOTE

• Perform Steps (1) through (3) for right side only.

• Do not remove divider panel.

(1) Remove screw (1) and locknut (2) from dash (3) and divider panel (4). Discard locknut.

(2) Remove screw (5) from divider panel (4) and dash (3).

NOTE

Do not remove washer fluid valve from divider panel.

(3) Lay divider panel (4) down inside glove box (6).
TM 9-2320-364-20-5

19-16 

19-7. WINDSHIELD WIPER IDLER SHAFT REPLACEMENT (CONT).

NOTE

Conlink is removed from idler shaft by prying off.

(4) Remove conlink (7) from idler shaft (8).
TM 9-2320-364-20-5

 19-17

NOTE

Steps (5) through (8) are performed outside cab.

(5) Remove cone (9) and boot (10) from idler shaft (8).

(6) Remove nut (11) from idler shaft (8).

(7) Remove washer (12) and gasket (13) from idler shaft (8). Discard gasket.

NOTE

When screws are removed, idler shaft will drop to floor of cab.

(8) Remove two screws (14) and idler shaft (8) from cab shell (15).

b. Installation.

NOTE

• Steps (1) through (3) are performed outside cab.

• Position idler shaft to stay in cab shell without support.

(1) Install idler shaft (8) in cab shell (15) with two screws (14).

(2) Install gasket (13), washer (12) and nut (11) on idler shaft (8).

(3) Install boot (10) and cone (9) on idler shaft (8).
TM 9-2320-364-20-5

19-18 

19-7. WINDSHIELD WIPER IDLER SHAFT REPLACEMENT (CONT).

NOTE

• Remaining steps are

performed inside cab.

• Conlink is installed by

snapping on idler shaft.

(4) Install conlink (7) on idler shaft (8).

NOTE

Remaining steps are for right 

side only. For left side,

continue with c. Follow-On

Maintenance.

(5) Position divider panel (4) inside glove

box (6).

(6) Install divider panel (4) to dash (3) with

screw (5).

(7) Install screw (1) and locknut (2) in divider

panel (4) and dash (3). Tighten locknut to

23 lb-ft (31 N.

m).

c. Follow-On Maintenance:

• Install wiper arm, (Para 19-5).

• Install instrument panel (left idler shaft only), (Para 7-13).

• Check operation of wipers, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 19-19

Material/Parts

Sealing Compound (Item 77, Appendix C)

Solution, Soap (Item 86, Appendix C)

Tags, Identification (Item 88, Appendix C)

Washer Fluid (Item 98, Appendix C)

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

19-8. WINDSHIELD WASHER RESERVOIR AND BRACKET REPAIR.

Material/Parts

Gasket (Item 66, Appendix F)

Locknut (3) (Item 131, Appendix F)

Screw, Self-locking (2) (Item 319, Appendix F)

a. Removal.

NOTE

Tag and mark hoses prior to removal.

(1) Slide clamp (1) up on hose (2) and remove hose from hose connector (3).

NOTE

Perform Step (2) if relief valve is present.

(2) Remove hose (4) from relief valve (5).

(3) Remove windshield washer reservoir (6) from windshield washer reservoir bracket (7).
TM 9-2320-364-20-5

19-20 

19-8. WINDSHIELD WASHER RESERVOIR AND BRACKET REPAIR (CONT).

(4) Remove two lock screws (8) and bracket (9)

from cab (10). Discard lock screws.

(5) Remove three locknuts (11), screws (12) and

windshield washer reservoir bracket (7) from

bracket (9). Discard locknuts.

NOTE

Perform Step (6) if foam gaskets

are damaged.

(6) Remove two foam gaskets (13) from

windshield washer reservoir bracket (7).

b. Disassembly.

(1) Remove cover assembly (1) from windshield

washer reservoir (2).

(2) Remove umbrella valve (3) from cover

assembly (1).

(3) Remove rubber tubes (4) and (5) and plastic

tube (6) from washer pump (7).

(4) Remove screen (8) from washer pump (7).

(5) Remove rubber tubes (4) and (5) from cover

assembly (1).

(6) Remove two connectors (9) from rubber

tubes (4) and (5).

(7) Remove two grommets (10) from cover

assembly (1).

c. Cleaning/Inspection.

(1) Clean screen and inspect for damage.

(2) Inspect umbrella valve and rubber tubes for

tears, cracking or damage.

(3) Inspect gasket on cover assembly for tears,

cracking or damage.

(4) Inspect condition of two foam gaskets inside

reservoir bracket. Replace if flattened or

missing.
TM 9-2320-364-20-5

 19-21

d. Assembly.

(1) Install two grommets (10) in cover

assembly (1).

(2) Install two connectors (9) on rubber

tubes (4) and (5).

(3) Lubricate rubber tubes (4) and (5) with soap

solution.

NOTE

The shorter rubber tube is

installed in the hole labeled VAL.

The longer rubber tube is

installed in the hole labeled NOZ.

Both rubber tubes should be

installed with approximately 3

inches (8 cm) sticking through

top of cover assembly.

(4) Install rubber tubes (4) and (5) in cover

assembly (1).

(5) Install screen (8) in washer pump (7).

(6) Position plastic tube (6) on rubber tube (5).

(7) Install rubber tubes (4) and (5) on washer

pump (7).

(8) Install umbrella valve (3) on cover

assembly (1).

(9) Install cover assembly (1) on windshield

washer reservoir (2).
TM 9-2320-364-20-5

19-22 

19-8. WINDSHIELD WASHER RESERVOIR AND BRACKET REPAIR (CONT).

e. Installation.

NOTE

Perform Step (1) if foam gaskets

were removed

(1) Install two four inch (10 cm) foam gaskets (13)

on windshield washer reservoir bracket (7).

(2) Install windshield washer reservoir bracket

(7) on bracket (9) with three screws (12) and

locknuts (11).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(3) Apply sealing compound to threads of two

lock screws (8).

(4) Install bracket (9) on cab (10) using two lock

screws (8).

(5) Install windshield washer reservoir (6) in

windshield washer reservoir bracket (7).
TM 9-2320-364-20-5

 19-23

NOTE

Perform Step (6) if relief valve is

present.

(6) Install hose (4) on relief valve (5).

(7) Install hose (2) on hose connector (3).

(8) Slide clamp (1) down to secure hose (2).

f. Follow-On Maintenance:

• Fill windshield washer reservoir with washer fluid, (TM 9-2320-364-10).

• Check operation of windshield washer, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

19-24 

Materials/Parts

Locknut (4) (Item 106, Appendix F)

Screw, Self-Tapping (2) (Item 299, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Beacon light removed, (TM 9-2320-364-10)

Engine cover opened, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Torque (0 to 60 N.

m)

(Item 98, Appendix G)

19-9. BEACON BRACKET REPLACEMENT.

a. Removal.

(1) Remove two screws (1) and beacon bracket (2) from beacon mounting bracket (3). Discard screws.

(2) Remove quickedge (4) from beacon bracket (2).

NOTE

Lockwasher, ground wire and two washers may or may not be preseent in Step (3).

(3) With the aid of an assistant, remove four locknuts (5), lockwasher (6) and ground wire (7), four screws (8),

washers (9), two washers (10) and beacon mounting bracket (3) from cab (11). Discard lockwasher and

locknuts.

9 1

5

6

7

3

9

8

10

8

4

10 5

11

11

3

INSULATION 2
TM 9-2320-364-20-5

 19-25

b. Installation.

NOTE

If ground wire was removed, refer to para 7-49 to install.

(1) With the aid of an assistant, install beacon mounting bracket (3) on cab (11) with four screws (8), washers

(9) and locknuts (5).

(2) Install quickedge (4) on beacon bracket (2).

(3) Install beacon bracket (2) on beacon mounting bracket (3) with two screws (1).

c. Follow-On Maintenance:

• Close engine cover, (TM 9-2320-364-10).

• Install beacon light, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

3

4

1 8

11

9

5

2
TM 9-2320-364-20-5

19-26 

Materials/Parts

Sealing Compound (Item 71, Appendix C)

Tags, Identification (Item 87, Appendix C)

Locknut (2) (Item 140, Appendix F)

Lockwasher (Item 162, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Air system drained, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

19-10. AIR HORN REPLACEMENT.

a. Removal.

(1) Open front access cover (1).

(2) Support air horn bracket (2), remove two

screws (3), locknuts (4) and air horn bracket.

Discard locknuts.

NOTE

Tag and mark air line before

removing.

(3) Remove air line 2039 (5) from elbow (6).

2 3

5

6

4

1
TM 9-2320-364-20-5

 19-27

NOTE

Matchmark elbow to ensure

correct installation and position.

(4) Remove elbow (7) from air horn (8).

(5) Remove nut (9), lockwasher (10) and washer

(11) from air horn (8).

(6) Remove screw (12), lockwasher (13), nut

(14), gasket (15) and air horn (8) from

bracket (2). Discard lockwasher.

b. Installation.

(1) Install gasket (15), air horn (8) on bracket

(2) with nut (14), lockwasher (13), and

screw (12).

(2) Install washer (11), lockwasher (10), and nut

(9) on air horn (8).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(3) Coat threads of elbow (7) with pipe thread

sealing compound.

NOTE

Install fittings as noted prior to

removal.

(4) Install elbow (7) on air horn (8).

11

9

10

14

13

12

15

8

7

2
TM 9-2320-364-20-5

19-28 

19-10. AIR HORN REPLACEMENT (CONT).

(5) Connect air line 2039 (5) to elbow (6).

(6) Install air horn bracket (2) with two screws (3)

and locknuts (4).

(7) Close front access cover (1).

c. Follow-On Maintenance:

• Start engine, (TM 9-2320-364-10).

• Build up air pressure to 90 psi (621 kPa), (TM 9-2320-364-10).

• Check operation of air horn.

• Shut off engine, (TM 9-2320-364-10).

• Check connections for leaks.

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

2 3

5

6

4

1
TM 9-2320-364-20-5

 19-29

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Air system drained, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

19-11. AIR HORN VALVE REPLACEMENT.

Materials/Parts

Sealing Compound (Item 71, Appendix C)

Tags, Identification (Item 87, Appendix C)

Lockwasher (2) (Item 161, Appendix F)

a. Removal.

NOTE

Tag and mark air lines before

removal.

(1) Disconnect air line 2037 (1) from elbow (2).

(2) Disconnect air line 2039 (3) from elbow (4).

NOTE

Perform Step (3) if chain is

damaged.

(3) Spread S-hook (5) and disconnect chain (6)

from air horn valve (7).

NOTE

There may or may not be a

washer present in Step (4).

(4) Remove two screws (8), lockwashers (9),

washer (10) and air horn valve (7) from cab

wall (11). Discard lockwashers

NOTE

Matchmark all fittings and elbows

to ensure correct installation and

position.

(5) Remove elbow (2) from elbow (12).

(6) Remove elbow (12) from air horn valve (7).

(7) Remove elbow (4) from air horn valve (7).

(8) Remove screw (13) and chain (6) from cab

wall (11).

13

6

11

10 9

8

3

1

4

2

12

7

5
TM 9-2320-364-20-5

19-30 

19-11. AIR HORN VALVE REPLACEMENT (CONT).

b. Installation.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(1) Coat threads of elbow (12), elbow (2) and

elbow (4) with pipe thread sealing

compound.

NOTE

Install fittings as noted prior to

removal.

(2) Install elbows (12) and (2) on air horn valve

(7).

(3) Install elbow (4) on air horn valve (7).

NOTE

There may or may not be a

washer present in Step (4).

(4) Install air horn valve (7) on cab wall (6) with

two washers (10), lockwashers (9) and

screws (8).

(5) Connect air line 2039 (3) to elbow (4).

(6) Connect air line 2037 (1) to elbow (2).

NOTE

Perform Step (7) if chain was

removed.

(7) Attach chain (6) to air horn valve (7) and

close S-hook (5).

(8) Install chain (6) on cab wall (11) with screw

(13).

13

6

11

10 9

8

3

1

4

2

12

7

5
TM 9-2320-364-20-5

 19-31

c. Follow-On Maintenance:

• Start engine, (TM 9-2320-364-10).

• Build up air pressure to 90 psi (621 kPa), (TM 9-2320-364-10).

• Check operation of air horn.

• Shut off engine, (TM 9-2320-364-10).

• Check connections for leaks.

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

19-32 

Materials/Parts

Adhesive (Item 4, Appendix C)

Cable Ties (4) (Item 25, Appendix C)

Solution, Soap (Item 86, Appendix C)

Tape, Adhesive (Item 90, Appendix C)

Tape, Antiseizing (Item 93, Appendix C)

Clip, Cable (Item 23, Appendix F)

Gasket Strip (Item 69, Appendix F)

Lockwasher (2) (Item 159, Appendix F)

Lockwasher (6) (Item 163, Appendix F)

Nut, Push (2) (Item 217, Appendix F)

Screw Washer Assembly (6)

(Item 308, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Cab engine access panel removed, (Para 17-24)

Electronic Control Box (ECB) cover

removed, (Para 17-22)

Heater compartment access panel

removed, (Para 17-4)

Heater compartment front cover

removed, (Para 17-5)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 11, Appendix G)

Pan, Drain (Item 47, Appendix G)

19-12. HEATER ASSEMBLY REPLACEMENT.

Materials/Parts - Continued

Rubber Strip (Item 337, Appendix F)

Rubber Strip (Item 338, Appendix F)

a. Removal.

(1) Remove gasket strip (1) from upper plenums (2).
TM 9-2320-364-20-5

 19-33

(2) Remove six screw washer assemblies (3)

from upper plenums (2). Discard screw

washer assemblies.

(3) Remove three screws (4), washers (5),

lockwashers (6), clip (7) and upper plenums

(2). Discard lockwashers.

(4) Remove two push nuts (8) and

cabin/ventilator cable (9) from damper (10).

(5) Remove damper (10) from lower plenum

(11).

(6) Remove lower plenum (11) and rest it on

heater (12).

NOTE

Note locations of defroster

tubings before removal.

(7) Remove four cable ties (13) and remove

defroster tubings (14) from lower plenum

(11).

As tubes are removed plug or

tape all openings to keep out

contaminates. Failure to comply

may cause equipment damage.

(8) Cover openings in heater assembly (12) with

masking tape.

5 6

3

2

11

7

4

8

10

9

13

14

12

11
TM 9-2320-364-20-5

19-34 

19-12. HEATER ASSEMBLY REPLACEMENT (CONT).

NOTE

Valves are closed by turning clockwise.

(9) Close two valves (15) at right front of engine.

NOTE

Steps (10) through (13) are performed outside truck.

(10) Open front access cover (16) in front of truck.

NOTE

Approximately one pint (0.5 l) of coolant will drain from heater.

(11) Position drain pan under heater assembly (12).
TM 9-2320-364-20-5

 19-35

• Do not remove heater hoses when engine is hot; steam and hot coolant can escape and 

burn personnel.

• Use clean wiping rags or like material to remove heater hoses. Avoid using gloves. If hot

water soaks through gloves, personnel could be burned.

• Coolant is slippery and can cause falls and injury. Clean up spilled coolant immediately.

(12) Loosen hose clamp (17) and disconnect 

heater hose (18) from heater assembly (12).

(13) Loosen two hose clamps (19) and (20) and

disconnect hose (21) from heater

assembly (12).

As hoses are removed plug or 

tape all hoses and tubes to keep

out foreign matter. Failure to

comply may cause equipment

damage.

(14) Cover openings in two heater hoses (18) and

heater assembly (12) with masking tape.

NOTE

Remaining steps are performed inside cab.

(15) Remove clip (22) and defroster cable (23) from defroster lever rod (24). Discard clip.

(16) Remove six screws (25) and lockwashers (26) from heater assembly (12) and heater bracket (27). Discard

lockwashers.
TM 9-2320-364-20-5

19-36 

19-12. HEATER ASSEMBLY REPLACEMENT (CONT).

To prevent damage to coolant tubes on heater, pull heater assembly straight up.

NOTE

Grommets may come out with heater or stay with cab.

(17) With the aid of an assistant, remove heater assembly (12) and two grommets (28) from cab (29). Cap two

coolant tubes (30).

NOTE

Perform Step (18) if PVC foam strips are damaged.

(18) Remove and discard four PVC foam strips (31) from heater assembly (12).

b. Installation.

NOTE

Perform Step (1) if PVC foam strips were removed.

(1) Install four PVC foam strips (31) on heater assembly (12).

(2) Position two grommets (28) in cab (29) and coat with soap solution.

(3) With the aid of an assistant, position heater assembly (12) in cab (29) and remove caps from coolant 

tubes (30).

• To prevent damage to coolant tubes on heater, install heater assembly straight down.

• Ensure that grommets are not dislodged during installation. If grommets are not 

positioned properly, coolant tubes could be damaged.

(4) With the aid of an assistant, position heater assembly (12) coolant tubes (30) through grommets (28).
TM 9-2320-364-20-5

 19-37

(5) Install heater assembly (12) and heater

bracket (27) in cab (29) with six screws (25)

and lockwashers (26).

(6) Install defroster cable (23) on defroster lever

rod (24) with clip (22).

(7) Remove covers from openings in heater

assembly (12).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(8) Coat inner edge of four defroster tubes 

(14) with adhesive.

(9) Install four defroster tubes (14) on lower

plenum (11) with cable ties (13).

(10) Position lower plenum (11) on heater (12).

(11) Position damper (10) in lower plenum (11)

and install cab/ventilator cable (9) on

damper (10) with two push nuts (8).

8

10

9

13

14

12

11
TM 9-2320-364-20-5

19-38 

19-12. HEATER ASSEMBLY REPLACEMENT (CONT).

(12) Install upper plenums (2) on lower plenum

(11) with six screw washer assemblies (3).

(13) Install three screws (4), washers (5),

lockwashers (6), and clip (7) in upper

plenums (2).

(14) Install gasket strip (1) on upper plenums (2).

5 6

3

2

11

7

4
TM 9-2320-364-20-5

 19-39

NOTE

Steps (15) through (18) are performed outside of the truck.

(15) Remove four plugs from two heater hoses (18) and (21) and heater assembly (12).

(16) Install heater hose (18) on heater assembly (12) and tighten hose clamp (17).

(17) Install heater hose (21) on heater assembly (12) and tighten two hose clamps (19) and (20).

(18) Close front access cover (16).

NOTE

• Remaining steps are performed inside cab.

• Valves are opened by turning counterclockwise.

(19) Open two valves (15) at right front engine.

c. Follow-On Maintenance:

• Install heater front cover, (Para 17-5).

• Install heater compartment access panel, (Para 17-4).

• Install electronic control box cover, (Para 17-22).

• Install cab engine access panel, (Para 17-24).

• Fill radiator, (Para 2-9).

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

19-40 

Materials/Parts

Lockwasher (10) (Item 182, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Heater compartment access panel removed,

(Para 17-4)

Batteries disconnected, (Para 7-87)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

19-13. HEATER BLOWER MOTOR REPLACEMENT.

a. Removal.

(1) Remove six screws (1), lockwashers (2), washers (3), clip (4) and heater cover (5) from heater assembly

(6). Discard lockwasher.

(2) Remove two screws (7), lockwashers (8) and

washers (9). Discard lockwashers.

(3) Remove screw (10), lockwasher (11),

washer (12), wire (13) and lockwasher (14).

Discard lockwasher.

(4) Disconnect connector (15) from

resistor (16).

(5) Disconnect connector (17).

(6) Remove blower housing (18) from heater

case (19).
TM 9-2320-364-20-5

 19-41

(7) Remove six screws (20) and two foils (21) from blower housing (18).

NOTE

• Blower wheels may be difficult to pull off motor shaft.

• Note direction of arrow on motor indicating direction of shaft rotation.

• Note position of blower wheels on shafts.

(8) Remove four clamps (22) from two blower wheels (23) and blower wheels from motor (24) shafts.

(9) Remove screw (25), washer (26), motor strap (27), motor insulator (28) and motor (24) from blower

housing (18).

b. Installation.

(1) Position motor (24) in blower housing (18).

(2) Install motor insulator (28), motor strap (27), washer (26) and screw (25) on blower housing (18).

NOTE

• Ensure blower wheels are installed as noted prior to removal.

• Note direction of arrow on motor indicating direction of shaft rotation.

(3) Install two blower wheels (23) and four clamps (22) on motor (24) shaft so that edge of fins on outside

diameter are the leading edge when blower wheels rotate in direction indicated on motor.

(4) Install two foils (21) on blower housing (18) with six screws (20).
TM 9-2320-364-20-5

19-42 

19-13. HEATER BLOWER MOTOR REPLACEMENT (CONT).

(5) Position blower housing (18) in heater

case (19).

(6) Connect connector (15) to resistor (16).

(7) Connect connector (17).

(8) Install lockwasher (14), ground wire (13),

washer (12), lockwasher (1110) and screw

(10) on center mounting hole.

(9) Install two washers (9), lockwashers (8) and

screws (7) in outer mounting holes.

(10) Install heater cover (5) on heater 

assembly (6) with six washers (3),

lockwashers (2) clip (4) and screws (1).

c. Follow-On Maintenance:

• Install heater compartment access panel, (Para 17-4).

• Connect batteries, (Para 7-87).

• Check operation of heater, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

3

5

4

6

1

2
TM 9-2320-364-20-5

 19-43

Materials/Parts

Solution, Soap (Item 86, Appendix C)

Lockwasher (6) (Item 159, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Cab engine access panel removed, (Para 17-24)

Heater compartment access panel

removed, (Para 17-4)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Pan, Drain (Item 46, Appendix G)

19-14. HEATER CORE REPLACEMENT.

a. Removal. 

Allow engine to cool prior to removal of heater core to prevent burns and injury to personnel.

(1) Set heater panel bottom control (1) to HEAT position.
TM 9-2320-364-20-5

19-44 

19-14. HEATER CORE REPLACEMENT (CONT).

NOTE

• Remaining steps are performed inside cab.

• Valves are closed by turning clockwise.

(2) Close two valves (2) at right front of engine.

(3) Open front access cover (3).

• Use caution when removing hoses to prevent getting antifreeze in eyes or mouth, if

antifreeze does get in eyes or mouth, seek medical attention immediately.

• Do not remove heater hoses when engine is hot: steam and hot coolant can escape and 

may cause injury to personnel.

(4) Position drain pan under coolant hoses (4).

(5) Loosen two clamps (5). Remove and cap two hoses (4) from heater core inlet tubes (6).
TM 9-2320-364-20-5

 19-45

(6) Remove six screws (7), lockwashers (8), washers (9), clip (10) and heater cover (11) from heater assembly

(12). Discard lockwashers.

(7) Remove four screws (13) from heater control

panel (14).

(8) Rotate heater control panel (14)

counterclockwise enough for heater

core (15) to clear cables.

When heater core is removed,

coolant will drain out. To prevent

damage to electrical components,

cover all components with a thick

layer of cloths. Clean up spills

immediately.

(9) Remove heater core (15) from heater

assembly (16) and two grommets (17).

(10) Remove two grommets (17) from heater

assembly (16).

b. Installation.

(1) Drain heater core (15).

(2) Coat two grommets (17) with soap solution

and install in heater assembly (16).

(3) Coat heater core (15) inlet tubes with soap

solution.

(4) Install heater core (15) in heater

assembly (16).

(5) Install heater panel (14) and four

screws (13).
TM 9-2320-364-20-5

19-46 

19-14. HEATER CORE REPLACEMENT (CONT).

(6) Install heater cover (11) and clip (10) on

heater assembly (12) with six washers (9),

lockwashers (8) and screws (7).

(7) Install two hoses (4) with clamps (5) on inlet

tubes (6).

(8) Close front access cover (3).

9

11

10

12

7 8
TM 9-2320-364-20-5

 19-47

NOTE

• Remaining steps are performed

inside cab.

• Valves are opened by turning

counterclockwise.

(9) Open two valves (2) at right front of engine.

c. Follow-On Maintenance:

• Fill cooling system, (Para 2-9).

• Install heater compartment access panel, (Para 17-4).

• Connect batteries, (Para 7-87).

• Install cab engine access panel, (Para 17-24).

• Start engine and run until it reaches operating temperature, (TM 9-2320-364-10).

• Shut OFF engine, (TM 9-2320-364-10).

• Check for coolant leaks, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

19-48 

Material/Parts

Cable Ties (Item 25, Appendix C)

Sealing Compound (Item 72, Appendix C)

Locknut (2) (Item 106, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Cab engine access panel removed, (Para 17-24)

Electric Control Box (ECB) right side panel

removed, (Para 17-21)

Electronic Control Box (ECB) cover removed,

(Para 17-22)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Pan, Drain (Item 46, Appendix G)

19-15. HEATER HOSES AND FITTINGS REPLACEMENT.

a. Removal.

Extreme care should be taken when removing heater hoses if water temperature gage reads

above 180 degrees F (82 degrees C). Contact by steam or hot coolant may result in injury or

death to personnel.

NOTE

• Remove cable ties as needed.

• Place drain pan under hose.

• Remaining steps are performed inside cab.

• Valves are closed by turning clockwise.

(1) Close heater coolant shut off valve (1) on thermostat housing (2).

(2) Close heater coolant shut off valve (3) on oil cooler (4).

(3) Remove hose clamp (5) and return hose (6) from heater coolant shut off valve (1).

(4) Remove hose clamp (7) and supply hose (8) from heater coolant shut off valve (3).
TM 9-2320-364-20-5

 19-49

(5) Remove locknut (9), screw (10) and two cushion clips (11) from bracket (12). Discard locknut.

(6) Remove locknut (13), screw (14) and cushion clip (15) from heater control valve bracket (16). Discard

locknut.

(7) Remove hose clamp (17) and supply hose (8) from fitting (18).

(8) Remove fitting (18) from heater control valve bracket (16).

(9) Loosen two hose clamps (19) and remove supply hose (20) from heater control valve (21).

(10) Remove supply hose (20) from truck.
TM 9-2320-364-20-5

19-50 

19-15. HEATER HOSES AND FITTINGS REPLACEMENT (CONT).

(11) Remove hose clamp (22) and return hose (6) 

from heater core (23).

(12) Remove return hose (6) from truck.

(13) Remove hose clamp (24) and supply

hose (25) from heater core (23).

(14) Remove supply hose (25) from truck.

b. Installation.

(1) Install supply hose (25) on heater core (23)

with hose clamp (24).

(2) Install return hose (6) on heater core (23)

with hose clamp (22).

(3) Install supply hose (20) on heater control

valve (21) with two hose clamps (19).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(4) Apply sealing compound on threads of

fitting (18).

(5) Install fitting (18) in heater control valve

bracket (16).

(6) Install supply hose (8) on fitting (18) with

hose clamp (17).

(7) Install screw (14), cushion clip (15) and

locknut (13) on heater control valve

bracket (16).
TM 9-2320-364-20-5

 19-51

(8) Install screw (10), two cushion clips (11) and

locknut (9) on bracket (12).

(9) Install supply hose (8) and hose clamp (7) on

heater coolant shut off valve (3).

(10) Install return hose (6) and hose clamp (5) on

heater coolant shut off valve (1).

(11) Open heater coolant shut off valve (3) on oil

cooler (4).

(12) Open heater coolant shut off valve (1) on

thermostat housing (2).

c. Follow-On Maintenance:

• Check radiator coolant level, (Para 6-2).

• Start engine, (TM 9-2320-364-10).

• Check hoses and fittings for coolant leaks, (TM 9-2320-364-10).

• Shut OFF engine, (TM 9-2320-364-10).

• Install Electronic Control Box (ECB) right side panel, (Para 17-21).

• Install Electronic Control Box (ECB) cover, (Para 17-22).

• Install cab engine access panel, (Para 17-24).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

19-52 

Materials/Parts

Tape, Foam (Item 92, Appendix C)

Nut, Push On (Item 217, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Heater assembly removed, (Para 19-12)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

19-16. FRESH AIR BOX REPLACEMENT.

a. Removal.

NOTE

Screen will fall when removed.

(1) Remove 14 screws (1) from fresh air box (2), screen (3) and deflector plate (4).

(2) Remove screw (5), clip (6), push on nut (7) and cable (8) from fresh air box (2) and actuator rod (9).

Discard push on nut.

NOTE

Perform Step (3) if foam tape is damaged.

(3) Remove and discard foam tape (10) from fresh air plate (11).
TM 9-2320-364-20-5

 19-53

b. Installation.

NOTE

Perform Step (1) if foam tape was removed.

(1) Install two 16 in. (41 cm) pieces foam tape (10) on fresh air plate (11).

NOTE

Ensure lever on heater panel is set to RECIRC.

(2) Install cable (8) on fresh air box (2) and actuator rod (9) with screw (5), clip (6) and heater clip (7).

NOTE

• Ensure that fresh air plate works properly. When heater panel is set to RECIRC, fresh air

plate should be closed firmly against screen opening. When heater panel is set to F/A, 

fresh air plate should be fully open.

• Ensure that deflector edge is positioned as shown.

(3) With the aid of an assistant, hold screen (3) and deflector plate (4) and loosely install fresh air box (2) with

14 screws (1). Do not tighten screws.

NOTE

Fresh air box should be installed as far back as possible to allow for installation of heater

assembly.

(4) While pulling fresh air box (2) toward rear as far as possible, tighten 14 screws (1) until snug.

c. Follow-On Maintenance:

• Install heater assembly, (Para 19-12).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

19-54 

Materials/Parts

Solution, Soap (Item 86, Appendix C)

Tags, Identification (Item 88, Appendix C)

Locknut (2) (Item 106, Appendix F)

Nut, Push On (2) (Item 217, Appendix F)

Screw Washer Assembly (3) (Item 308, Appendix F)

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Heater compartment access panel removed,

(Para 17-4)

Electrical Control Box (ECB) right side panel

removed, (Para 17-21)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

19-17. HEATER CONTROL PANEL REPAIR.

a. Removal.

Use care not to pull wiring away from switches when removing switch panel. Damage to

equipment may occur.

NOTE

Tag and mark wires prior to removal.

(1) Remove six screws (1) and lay switch panel (2) to side.
TM 9-2320-364-20-5

 19-55

(2) Disconnect connector (3) from

connector (4).

(3) Remove four screws (5) and pull heater

control panel (6) out from heater

compartment (7).

(4) Remove lamp socket (8) from heater

panel (6).

(5) Remove lamp (9) from lamp socket (8).

(6) Remove wires 1082, red, brown and orange

(10) from switch (11).

(7) Loosen screw (12) and remove knob (13)

from switch (11).

(8) Remove nut (14) and switch (11) from heater

control panel (6).

(9) Remove screw (15), nut (16) and DEF/CAB

control cable (17) from lever (18).

(10) Remove three screw and washer assemblies

(19) from upper plenum (20). Discard

screw and washer assemblies.

(11) Remove two screws (21), washer (22),

lockwasher (23) and upper plenum (20)

from heater (24). Discard lockwasher.

19

20

24

21

22

23

ORANGE RED

WIRE 1082 BROWN

7 8 9

5

12

14

11 6

3 10

4

13
TM 9-2320-364-20-5

19-56 

19-17. HEATER CONTROL PANEL REPAIR (CONT).

(12) Remove screw (25), lockwasher (26),

washer (27), clip (28) and cabin/ventilator

cable (29) from heater (24). Discard

lockwasher.

(13) Remove two push on nuts (30) and cable

(29) from damper (31). Discard push on

nuts.

(14) Remove nut (32) and lockwasher (33) from

cabin/ventilator cable (29). Discard

lockwasher.

(15) Remove cable (29) from control bracket (6).

(16) Remove lockwasher (33) from

cabin/ventilator cable (29). Discard

lockwasher.

(17) Loosen screw (34) and remove MC1

connector (35) from connector (36).

(18) Loosen screw (37) and remove MC2

connector (38) from connector (39).

(19) Remove two locknuts (40) and lower

connector (39) from bracket (41). Discard

locknuts.

(20) Loosen clamp screw (42) and remove

RECIRC/FA control cable (43) from 

clamp (44) and lever (45).

27

28

24 32

6

33

26 25

30 31

30 29
TM 9-2320-364-20-5

 19-57

(21) Loosen clamp screw (46) and remove OFF/HEAT control cable (47) from heater control valve (48) and

clamp (49).

(22) Carefully pull OFF/HEAT control

cable (47) through grommet (50).

(23) Remove heater control panel (6) with cables

from heater compartment (7).

b. Disassembly.

NOTE

• All three knobs are removed

the same way.

• Tag and mark cables before

removal.

(1) Remove three screws (1) and knobs (2) from

levers (3).

(2) Remove control plate (4) from control

bracket (5).

(3) Remove three screws (6), clamps (7) and

cables (8) from control bracket (5).

(4) Remove three clips (9) and cables (8) from

levers (3). Discard clips.

50

7

6

47

7

6

8

5

2

3 9

1

4
TM 9-2320-364-20-5

19-58 

19-17. HEATER CONTROL PANEL REPAIR (CONT).

c. Cleaning/Inspection.

(1) Inspect all wires and cables for kinks.

(2) Inspect screws and nuts for stripped threads.

(3) Inspect rotary switch for loose or cracked

terminals.

(4) Replace all damaged parts.

d. Assembly.

(1) Install three cables (8) and clips (9) on 

levers (3).

(2) Install three cables (8), clamps (7) and

screws (6) on control bracket (5).

(3) Position control plate (4) on control bracket

(5).

(4) Install three knobs (2) and screws (1) on

levers (3).

e. Installation.

(1) Position heater control panel (6) in 

heater compartment (7).

(2) Coat grommet (50) with soap solution.

(3) Install OFF/HEAT control cable (47) in

grommet (50) on bottom right side of 

heater compartment (7).

50

7

6

47

7

6

8

5

2

3 9

1

4
TM 9-2320-364-20-5

 19-59

(4) Position OFF/HEAT cable (47) in 

clamp (49) and lever of heater control

valve (48). Do not tighten clamp screw (46).

(5) Hold heater control valve (48) lever forward

and set heater control panel OFF/HEAT slide

control on HEAT. Back control off HEAT

setting 1/4 in. (6 mm) and tighten clamp

screw (46).

(6) Position RECIRC/FA control cable (43) on

lever (45) and in clamp (44). Do not tighten

clamp screw (42).

(7) Hold lever (45) forward and set heater

control panel RECIRC/FA slide control on

FA. Tighten clamp screw (42) on clamp (44)

and cable (43).
TM 9-2320-364-20-5

19-60 

19-17. HEATER CONTROL PANEL REPAIR (CONT).

(8) Install connector (39) on bracket (41) with

two locknuts (40).

(9) Install MC2 connector (38) on

connector (39) with screw (37).

(10) Install MC1 connector (35) on

connector (36) with screw (34).

(11) Position DEF/CAB cable (17), nut (16) and

screw (15) on lever (18). Do not tighten

screw.

(12) Hold lever (18) forward and set heater

control panel DEF/CAB slide control on

CAB. Tighten screw (15) and nut (16) on

DEF/CAB cable (17).
TM 9-2320-364-20-5

 19-61

(13) Install nut (31) and lockwasher (32) on

cabin/ventilator cable (29).

(14) Install cabin/ventilator cable (29) on control

bracket (6) with lockwasher (32) and nut

(31).

(15) Install switch (11) and nut (14) on heater

control panel (6).

(16) Install wires 1082, red, brown and 

orange (10) on switch (11).

(17) Install knob (13) on switch (11) and tighten

screw (12).

(18) Install lamp (9) in lamp socket (8).

(19) Install lamp socket (8) in heater control

panel (6).

(20) Install heater control panel (6) on heater

compartment (7) with four screws (5).

(21) Connect connector (4) to connector (3).

(22) Install cabin/ventilator cable (29) on

damper (31) with two push on nuts (30).

(23) Install cabin/ventilator cable (29) on heater

(24) with clip (28), screw (25), lockwasher

(26) and washer (27).

27

28

24 26 25

30 31

30 29

31

6

32

29

ORANGE RED

WIRE 1082 BROWN

7 8 9

5

12

14

11 6

3 10

4

13
TM 9-2320-364-20-5

19-62 

19-17. HEATER CONTROL PANEL REPAIR (CONT).

(24) Install upper plenum (20) in heater

compartment (7) and heater (24) with three

screw and washer assemblies (19), screw

(21), lockwasher (23) and washer (22).

(25) Operate heater control panel controls for

correct operation.

(26) Install switch panel (2) with six screws (1).

f. Follow-On Maintenance:

• Install heater compartment access panel, (Para 17-4).

• Install Electronic Control Box (ECB) right side panel, (Para 17-21).

• Connect batteries, (Para 7-87).

• Check heater operation, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

19

20

24

21

22

23
TM 9-2320-364-20-5

 19-63

Materials/Parts

Sealing Compound (Item 72, Appendix C)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Cab engine access panel removed, (Para 17-24)

Electronic Control Box (ECB) right side panel

removed, (Para 17-21)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Drain Pan (Item 47, Appendix G)

19-18. HEATER CONTROL VALVE REPLACEMENT.

a. Removal.

Allow engine to cool prior to removal of valve to prevent burns and possible injury to

personnel.

(1) Set heater control panel OFF/HEAT control (1) to HEAT position.
TM 9-2320-364-20-5

19-64 

19-18. HEATER CONTROL VALVE REPLACEMENT (CONT).

NOTE

• Remaining steps are performed inside cab.

• Valves are closed by turning clockwise.

(2) Close two valves (2) at right front of engine.

(3) Loosen clamp screw (3) and remove control cable (4) from clamp (5) and valve lever (6).
TM 9-2320-364-20-5

 19-65

Do not remove heater hoses when engine is hot; steam and hot coolant can escape and may

cause injury to personnel.

(4) Position drain pan under valve (7).

(5) Loosen clamp (8) and remove hose (9) from valve (7).

(6) Remove heater control valve (7) from fitting (10).

b. Installation.

Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and

are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use 

in a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, 

wash immediately with soap and water.

(1) Apply sealing compound on heater control

valve (7).

NOTE

Lever must be on bottom of 

valve when valve is installed.

(2) Install heater control valve (7) in 

fitting (10).

(3) Install heater hose (9) with clamp (8) on

heater control valve (7). Tighten clamp

securely.

(4) Open two valves (2) at right front of engine.
TM 9-2320-364-20-5

19-66 

19-18. HEATER CONTROL VALVE REPLACEMENT (CONT).

(5) Set heater control panel OFF/HEAT

control (1) to OFF position.

(6) Pull heater control valve lever (6) rearward

against stop.

(7) Install cable (4) on valve lever (6) while

keeping lever in rearward position.

(8) Install cable (4) in clamp (5) and tighten

screw (3).

c. Follow-On Maintenance:

• Check coolant level, (TM 9-2320-364-10).

• Start engine, (TM 9-2320-364-10).

• Check for coolant leaks, (TM 9-2320-364-10).

• Shut OFF engine, (TM 9-2320-364-10).

• Install cab engine access panel, (Para 17-24).

• Install Electronic Control Box (ECB) right side panel, (Para 17-21).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 19-67

Materials/Parts

Adhesive Sealant (Item 3, Appendix C)

Cable Ties (Item 26, Appendix C)

Gasket Strip (Item 69, Appendix F)

Locknut (Item 140, Appendix F)

Lockwasher (2) (Item 159, Appendix F)

Nut, Push On (2) (Item 217, Appendix F)

Screw Washer Assemblies (6) (Item 308, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Heater compartment access panel removed,

(Para 17-4)

Instrument panel removed, (Para 7-13)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

19-19. HEATER/DEFROSTER TUBING REPLACEMENT.

a. Removal.

(1) Remove gasket strip (1) from upper plenums (2).

(2) Remove six screw washer assemblies (3) from upper plenums (2). Discard screw washer assemblies.

(3) Remove two screws (4), washers (5), lockwashers (6) and two upper plenums (2) from heater (7). Discard

lockwashers.

1

3

5 6

4

2

7
TM 9-2320-364-20-5

19-68 

19-19. HEATER/DEFROSTER TUBING REPAIR (CONT).

(4) Remove two push nuts (8) and cabin

ventilator cable (9) from damper (10).

Discard push nuts.

(5) Remove damper (10) from lower plenum

(11).

(6) Remove lower plenum (11) from front of

heater (7) and rest lower plenum on top of

heater.

(7) Remove four cable ties (12), defroster tubing

(13), (14), (15) and (16) from lower plenum

(11).

8

10

9

11

12

13

14

15

16

7

11
TM 9-2320-364-20-5

 19-69

(8) Remove two cable ties (12), defroster tubing

(14), (15) and remaining adhesive from

defroster plenum (17).

(9) Remove cable tie (12), left outer defroster

tubing (13) and remaining adhesive from

defroster plenum (17).

(10) Remove screws (18) and (19), bracket (20)

and locknut (21) and pull plate (22) back.

Discard locknut.

(11) Remove cable tie (12), right outer defrost

tubing (16) and remaining adhesive from

defroster plenum (17).
TM 9-2320-364-20-5

19-70 

19-19. HEATER/DEFROSTER TUBING REPAIR (CONT).

(12) Remove cable tie (12), right cab heat tubing

(23) and remaining adhesive from heater

(7).

(13) Remove cable tie (12) and right cab heat

tubing (23) from manifold tubing (24).

(14) Remove cable tie (12), tubing (25) and any

remaining adhesive from heater (7).
TM 9-2320-364-20-5

 19-71

(15) Remove left cab heat tubing (25) from

throttle bracket (26) and treadle valve (27).

b. Installation.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a wellventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and

water.

(1) Apply small, even bead of adhesive inside

one end of left cab heat tubing (25) and

install on heater (7) with cable tie (12).

(2) Route tubing (25) between throttle bracket

(26) and treadle valve (27) pointing towards

drivers area.
TM 9-2320-364-20-5

19-72 

19-19. HEATER/DEFROSTER TUBING REPAIR (CONT).

(3) Install right cab heat tubing (23) to manifold

tubing (24) with cable tie (12).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a wellventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and

water.

(4) Apply small, even bead of adhesive inside

right cab heat tubing (23) and install on

heater (7) with cable tie (12).

(5) Apply small, even bead of adhesive inside

right outer defroster tubing (16) and install

on plenum (17) with cable tie (12).

(6) Install plate (22) and bracket (20) using

screw (19), locknut (21) and screw (18).
TM 9-2320-364-20-5

 19-73

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a wellventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(7) Apply small, even bead of adhesive inside

left outer defroster tubing (13) and install on

defroster plenum (17) with cable tie (12).

(8) Apply small, even bead of adhesive inside

defroster tubing (14) and (15) and install on

plenum (17) with cable ties (12).

NOTE

DEF/CAB and recipr/FA cables

are positioned between inner

defrost tubings and between

upper plenums.

(9) Position lower plenum (11) on top of heater

(7).

(10) Apply small, even bead of adhesive inside

defroster tubing (13), (14), (15) and (16)

and install on lower plenum (11) with cable

ties (12).

12

13

14

15

16

7

11
TM 9-2320-364-20-5

19-74 

19-19. HEATER/DEFROSTER TUBING REPAIR (CONT).

(11) Position lower plenum (11) on heater (7).

(12) Install damper (10) in lower plenum (11).

(13) Install cabin/ventilator cable (9) on damper

(10) with two push nuts (8).

10

7

11

8

10

9
TM 9-2320-364-20-5

 19-75

NOTE

DEF/CAB and RECIPR/FA

cables are positioned between

inner defrost tubings and between

upper plenums.

(14) Install upper plenums (2) on lower plenum

(11) and heater (7) with six screw washer

assemblies (3) and two screws (4), washers

(5) and lockwashers (6).

(15) Install gasket strip (1) on plenums (2).

c. Follow-On Maintenance.

• Install instrument panel, (Para 7-13).

• Install heater compartment access panel, (Para 17-4).

• Check operation of heater and defroster, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

1

3

5 6

4

2

7

1

1
TM 9-2320-364-20-5

19-76 

Material/Parts

Cloth, Cleaning (Item 31, Appendix C)

Solvent, Drycleaning (Item 87, Appendix C)

This task covers:

a. Type 1 Data Plate Replacement c. Type 3 Data Plate Replacement

b. Type 2 Data Plate Replacement d. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Drill, Electric, Portable (Item 17, Appendix G)

Drill Set, Twist (Item 19, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Tool Kit, Blind Rivet (Item 72, Appendix G)

19-20. DATA PLATE REPLACEMENT.

NOTE

• Subparagraphs a. through c. show all typical data plates used on the truck.

• Refer to TM 9-2320-364-10 for location of all data plates.

a. Type 1 Data Plate Replacement.

(1) Removal. Remove four screws (1) and data plate (2) from frame (3).

(2) Installation. Install data plate (2) on frame (3) with four screws (1).
TM 9-2320-364-20-5

 19-77

b. Type 2 Data Plate Replacement.

(1) Removal. Using a 1/8 in. drill bit, remove four rivets (1) and data plate (2) from frame (3). Discard rivets.

(2) Installation. Install data plate (2) on frame (3) with four rivets (1).

c. Type 3 Data Plate Replacement.

(1) Removal. Pry data plate (1) away from frame (2).
TM 9-2320-364-20-5

19-78 

19-20. DATA PLATE REPLACEMENT (CONT).

(2) Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

(a) Make sure surface is clean of any dirt or debris.

(b) Clean with lint free cloth and drycleaning solvent.

(3) Installation. Peel paper off data plate (1)

and place on frame (2).

d. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 19-79/(19-80 blank)

Materials/Parts

Lockwasher (2) (Item 180, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

19-21. WEIGHT CLASSIFICATION SIGN REPLACEMENT.

a. Removal. Remove two nuts (1), lockwashers (2), screws (3) and weight classification sign (4) from two

brackets (5). Discard lockwashers.

b. Installation. Install weight classification sign (4) on two brackets (5) with screws (3), lockwashers (2), 

and nuts (1).

c. Follow-On Maintenance:

• Removal wheel chocks, (TM 9-2320-364-10).

END OF TASK

TM 9-2320-364-20-5

 20-1

CHAPTER 20

HYDRAULIC SYSTEM MAINTENANCE

Para Contents Page

20-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

20-2 Main Hydraulic Pump Driveshaft Repair 20-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20-3 Main Hydraulic Hoses Replacement 20-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20-4 Air-To-Oil Cooler Replacement 20-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20-5 Fan Control Solenoid Valve Repair 20-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20-6 High Pressure Hydraulic Filter Replacement 20-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20-7 High Pressure Hydraulic Filter Head Assembly Replacement 20-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20-8 High Pressure Hydraulic Filter Head Repair 20-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20-9 Main Hydraulic Filter Replacement 20-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20-10 Main Hydraulic Reservoir Filter Assembly Replacement 20-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20-11 Main Hydraulic Reservoir Service 20-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20-12 Main Hydraulic Reservoir Replacement 20-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20-13 Hydraulic Reservoir Strainer Replacement 20-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20-14 Hydraulic Reservoir Filler Breather Replacement 20-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20-15 Hydraulic Fluid Level Gage Replacement 20-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20-16 Hydraulic Drain Hose Kit Installation 20-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20-1. INTRODUCTION.

This chapter contains maintenance instructions for removing, replacing, installing and adjusting components of the

hydraulic system as authorized by the Maintenance Allocation Chart (MAC) at the Unit Maintenance level.
TM 9-2320-364-20-5

20-2 

Materials/Parts

Cloth, Cleaning (Item 31, Appendix C)

Grease, General Purpose (Item 43, Appendix C)

Sealing Compound (Item 77, Appendix C)

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-on Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Cab engine access panel removed, (Para 17-24)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Hammer, Hand Soft Plastic

(Item 33, Appendix G)

Vise, Machinist’s (Item 75, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0-237 N.

m])

(Item 95, Appendix G)

20-2. MAIN HYDRAULIC PUMP DRIVESHAFT REPAIR.

Materials/Parts - Continued

Solvent, Drycleaning (Item 87, Appendix C)

Lockwasher (4) (Item 170, Appendix F)

U-Joint Kit (Item 341, Appendix F)

a. Removal.

NOTE

Matchmark yoke ends prior to removal.

(1) Remove four screws (1) and two straps (2) from pump drive shaft (3) and end yoke (4).

(2) Remove four screws (5) and lockwashers (6) from pump drive shaft (3) and engine (7). Discard

lockwashers.

(3) Remove pump drive shaft (3) from end yoke (4) and engine (7).
TM 9-2320-364-20-5

 20-3

b. Disassembly.

(1) Remove grease fitting (1) from slip yoke (2).

NOTE

Matchmark slip yoke and splined

yoke to aid in installation.

(2) Loosen dust cap (3) and separate splined

yoke (4) and slip yoke (2).

(3) Remove two bearing caps (5) from 

U-joint (6). Discard bearing caps.

(4) Place splined yoke (4) in vise.

Use care when removing 

retaining rings. Retaining rings 

are under spring tension and can 

act as projectiles when released 

and could cause severe eye 

injury.

(5) Remove two spring clips (7) from splined

yoke (4).

(6) Using a soft-faced hammer, drive U-joint (6)

toward bearing cap (8) until it bottoms

against splined yoke (4).

(7) Rotate splined yoke (4) 1/2 turn in vise.

(8) Using a soft-faced hammer, drive U-joint (6)

toward bearing cap (9) until it bottoms

against splined yoke (4).

(9) Remove U-joint (6) from splined yoke (4).

Discard U-joint.

(10) Using a punch, remove bearing caps (8)

and (9) from splined yoke (4) . Discard

bearing caps.
TM 9-2320-364-20-5

20-4 

20-2. MAIN HYDRAULIC PUMP DRIVESHAFT REPAIR (CONT).

Use care when removing retaining rings. Retaining rings are under spring tension and can act 

as projectiles when released and could cause severe eye injury.

(11) Remove two spring clips (10) from slip yoke (2). Discard spring clips.

(12) Using a soft-faced hammer, drive U-joint (11) toward bearing cap (12) until it bottoms against slip

yoke (2).

(13) Rotate slip yoke (2) 1/2 turn in vise.

(14) Using a soft-faced hammer, drive 

U-joint (11) toward bearing cap (13) 

until it bottoms against slip yoke (2).

(15) Separate slip yoke (2) from bracket (14) 

and U-joint (11).

(16) Using a punch, remove bearing caps (12) 

and (13) from slip yoke (2). Discard 

bearing caps.

(17) Remove slip yoke (2) from vise.

Use care when removing

retaining rings. Retaining rings

are under spring tension and can

act as projectiles when released

and could cause severe eye injury.

(18) Remove two spring clips (15) from

bracket (14) and U-joint (11).

(19) Place bracket (14) and U-joint (11) in vise.

(20) Using a soft-faced hammer, drive U-joint (11)

toward bearing cap (16) until it bottoms

against bracket (14).

(21) Rotate bracket (14) 1/2 turn in vise.

(22) Using a soft-faced hammer, drive U-joint (11)

toward bearing cap (17) until it bottoms

against bracket (14).

(23) Remove U-joint (11) from bracket (14).

(24) Remove bearing caps (16) and (17) from

bracket (14).

(25) Remove bracket (14) from vise.
TM 9-2320-364-20-5

 20-5

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc).

(1) Clean all parts with drycleaning solvent.

(2) Wipe parts with a clean, lint free cloth.

(3) Inspect all parts for cracks, gouges and pitting.

(4) Inspect shaft for free play caused by worn slip yoke or shaft splines.

(5) Replace any cracked or worn parts.

d. Assembly.

NOTE

Ensure yokes are aligned with

match marks made during

disassembly.

(1) Place bracket (14) in vise.

(2) Position U-joint (11) in bracket (14).

Needle bearings may fall out

during assembly, use caution to

avoid damage to equipment.

(3) Install bearing caps (16) and (17) on 

U-joint (11) in bracket (14).
TM 9-2320-364-20-5

20-6 

20-2. MAIN HYDRAULIC PUMP DRIVESHAFT REPAIR (CONT).

Use care when installing 

retaining rings. Retaining rings 

are under spring tension and can 

act as projectiles when released 

and could cause severe eye 

injury.

NOTE

Clips are properly installed when

seated in grooves in yoke.

(4) Install two clips (15) in bracket (14).

(5) Remove bracket (14) from vise.

(6) Position slip yoke (2) in vise.

(7) Position U-joint (11) in slip yoke (2).

Needle bearings may fall out

during assembly, use caution to

avoid damage to equipment.

(8) Install bearing caps (12) and (13) on

U-joint (11), in slip yoke (2).

Use care when installing retaining

rings. Retaining rings are under

spring tension and can act as

projectiles when released and

could cause severe eye injury.

NOTE

Clips are properly installed when

seated in grooves in yoke.

(9) Install two clips (10) in slip yoke (2).
TM 9-2320-364-20-5

 20-7

(10) Position U-joint (6) in splined yoke (4).

Needle bearings may fall out

during assembly, use caution 

during assembly to avoid damage

to equipment.

(11) Install bearing caps (8) and (9) on 

U-joint (6) in splined yoke (4).

Use care when installing 

retaining rings. Retaining rings 

are under spring tension and can 

act as projectiles when released 

and could cause severe eye 

injury.

NOTE

Clips are properly installed when

seated in grooves in yoke.

(12) Install two clips (7) in splined yoke (4).

(13) Remove splined yoke (4) from vise.

(14) Install bearing caps (5) on U-joint (6).

(15) Install dust cap (3) and splined yoke (4) on

slip yoke (2).

(16) Install grease fitting (1) in slip yoke (2).
TM 9-2320-364-20-5

20-8 

20-2. MAIN HYDRAULIC PUMP DRIVESHAFT REPAIR (CONT).

e. Installation.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(1) Coat threads of four screws (5) with sealing

compound.

(2) Install pump driveshaft assembly (3) on

engine (7) with four lockwashers (6) and

screws (5). Tighten screws to 60 lb-ft (81

N.

m).

(3) Coat threads of four screws (1) with sealing

compound.

(4) Install pump driveshaft assembly (3) on end

yoke (4) with two straps (2) and four

screws (1). Tighten screws to 25 to 30 lb-ft

(34 to 41 N.

m).

f. Follow-On Maintenance:

• Install cab engine access panel, (Para 17-24).

• Connect batteries, (Para 7-87).

• Start engine, (TM 9-2320-364-10).

• Check driveshaft operation (operate LHS), (TM 9-2320-364-10).

• Shut OFF engine, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 20-9

Materials/Parts

Cable Ties (Item 26, Appendix C)

Tags, Identification (Item 88, Appendix C)

This task covers:

a. Hose Locations b. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Hydraulic reservoir drained, (Para 20-11)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

20-3. MAIN HYDRAULIC HOSES REPLACEMENT.

a. Hydraulic Hose Locations.

Equipment may be damaged by foreign matter if hoses, tubes and connectors are not plugged

and capped when removed.

NOTE

• This procedure shows the location of hydraulic hoses on the truck. It will never be

necessary to remove all hydraulic hoses at one time.

• As items are removed, cap and plug all hoses, tubes and connectors.

• Tag and mark all hoses, pipes and tubes before removal.

• Inspect all hoses, lines and fittings for cracks, bends, nicks, dents, stripping threads and

cuts. Replace all damaged parts.

• Remove and replace cable ties as required.

• Remove clamps and support brackets as required.
TM 9-2320-364-20-5

20-10 

20-3. MAIN HYDRAULIC HOSES REPLACEMENT (CONT).

Table 20-1. Main Hydraulic Hoses Location.

Hose No. From To

2049 Pump Compensator Front (1) Pump Right Side Forward T (2)

2899 Multifunction Manifold Right Bottom (3) SRW Bulkhead Rear (4)

2290 Fan Control Valve Front (5) Pump Left Rear (2)

2498 Hydraulic Reservoir Left Front Corner (6) Pump Forward Right (2)

2917 Return Line Manifold Left (7) LHS Disconnect Rear (8)

2773 Air to Oil Cooler Right Front (9) Hydraulic Reservoir Top Left (6)

2772 Multifunction Manifold Right Rear (3) Fan Motor (11)

2781 Hydraulic Reservoir Left Side (6) Pump Right Side Rear (2)

2295 Multifunction Manifold Top Rear (3) Pump Compensator Left (1)

2809 Multifunction Manifold Top Front (3) SRW Bulkhead Front Bottom (4)

2777 Multifunction Manifold Rear (3) LHS Disconnect Front (8)

2904 Multifunction Manifold Top Right (3) Return Line Manifold Top Forward (7)

2886 Return Line Manifold Left (7) SRW Bulkhead Front Top (4)

2918 Return Line Manifold Rear (7) Hydraulic Reservoir Rear Left (6)

2935 Pump Top Center (2) High Pressure Filter Rear (10)

2936 High Pressure Filter Front (10) Multifunction Manifold Right Top Center (3)

2291 Multifunction Manifold Forward Right Center (3) Fan Control Valve Rear (5)

2771 Fan Motor (11) Air to Oil Cooler Right Rear (9)

*2902 Multifunction Manifold Center Right (3) Crane (12)

*2776 Multifunction Manifold Bottom Right (3) Crane (12)

*2694 Crane (12) Hydraulic Reservoir Left Side (6)

*2724 Crane (13) Return Line Manifold Top Center (7)

* If equipped with Crane.
TM 9-2320-364-20-5

 20-11

TABLE 20-1. Main Hydraulic Hoses Location (Cont).

Hose No. From To

**2724 Interface 1 Return Line Manifold

**2724 Auxiliary Supply Valve Return Line Manifold

**2810 Auxiliary Supply Valve Interface

**2776 Interface Multi Function Manifold

**2902 Auxiliary Supply Valve Multi Function Manifold

** If equipped with Interface Kit.

b. Follow-On Maintenance:

• Fill main hydraulic reservoir, (Para 20-11).

• Remove wheel chocks, (TM 9-2320–364-10).

END OF TASK

TUBE 2724

TUBE 2810 TUBE 2810

HOSE 2724 TUBE 2724

HOSE 2810

TUBE 2724

TUBE 2810

HOSE 2776
TM 9-2320-364-20-5

20-12 

Materials/Parts

Cable Ties (Item 26, Appendix C)

Oil, Lubricating (Item 54, Appendix C)

Tags, Identification (Item 88, Appendix C)

Lockwasher (4) (Item 168, Appendix F)

Packing, Preformed (2) (Item 252, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Radiator grille assembly removed, (Para 17-14)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

Pan, Drain (Item 46, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Combination 1-1/2 in.

(Item 83, Appendix G)

Wrench, Combination 1-5/8 in.

(Item 84, Appendix G)

Wrench, Torque (0-60 N.

m)

(Item 98, Appendix G)

20-4. AIR-TO-OIL COOLER REPLACEMENT.

a. Removal.

• Prolonged contact with lubricating oil (MIL-L-2104) may cause a skin rash. Skin and

clothing that come in contact with lubricating oil should be thoroughly washed

immediately. Saturated clothing should be removed immediately. Areas in which

lubricating oil is used should be well-ventilated to keep fumes to a minimum.

• Ensure engine is cool before performing this task or severe burns from hot hydraulic fluid

may result.

• The main hydraulic system operates at pressures up to 3,675 psi (25,339 kPa). Never

disconnect any hydraulic line without first dropping pressure to zero. Failure to comply

may result in serious injury or death to personnel.

• Equipment may be damaged by foreign matter if hoses and tubes are not plugged and

capped when being removed.

• Prevent tubes on air-to-oil cooler from turning when disconnecting hoses. Failure to

comply will cause damage to equipment.

• The fins and core of air-to-oil cooler and radiator are easily damaged. Use extreme caution

when removing or damage to equipment may occur.
TM 9-2320-364-20-5

 20-13

NOTE

• Cap and plug all hoses and tubes during removal.

• Tag and mark all hoses prior to removal.

• Remove cable ties, clamps and support braces as required.

(1) Remove hose 2771 (1) and preformed packing (2) from air-to-oil cooler (3). Discard preformed packing.

(2) Remove hose 2773 (4) and preformed packing (2) from air-to-oil cooler (3). Discard preformed packing.

(3) Remove four screws (5), washers (6), plates

(7), eight tube supports (8) and air-to-oil

cooler (3) from front support (9) and rear

support (10).
TM 9-2320-364-20-5

20-14 

20-4. AIR-TO-OIL COOLER REPLACEMENT (CONT).

(4) Remove four screws (11), lockwashers (12),

washers (13), front support (9) and rear

support (10) from support brackets (14).

Discard lockwashers.

b. Installation.

• Prevent tubes on air-to-oil

cooler from turning when

connecting hoses. Failure to

comply will cause damage to

equipment.

• The fins and core of air-to-oil

cooler and radiator are easily

damaged. Use caution when

installing or damage to

equipment may occur.

(1) Install front support (9) and rear support 

(10) on support brackets (14) with four

screws (11), lockwashers (12) and 

washers (13).

(2) Install air-to-oil cooler (3) on front 

support (9) and rear support (10) with four

screws (5), washers (6), plates (7) and eight

tube supports (8).

(3) Apply lubricating oil to preformed 

packings (2).

(4) Install preformed packing (2) and hose 

2773 (4) to air-to-oil cooler (3).

(5) Install preformed packing (2) and hose 

2771 (1) to air-to-oil cooler (3).

c. Follow-On Maintenance:

• Install radiator grille assembly, (Para 17-14).

• Check and fill main hydraulic reservoir, 

(Para 2-9, Lubrication Table 2-3).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 20-15

Materials/Parts

Heatshrink (Item 48, Appendix C)

Oil, Hydraulic (Item 50, Appendix C)

Tags, Identification (Item 88, Appendix C)

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Electronic control box (ECB) removed,

(Para 17-23)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Crimping Tool (Item 13, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Airblow (Item 31, Appendix G)

Gun, Heat (Item 32, Appendix G)

Pan, Drain (Item 46, Appendix G)

Weatherpac Crimper (Item 76, Appendix G)

Wrench, Torque (0-60 N.

m)

(Item 98, Appendix G)

20-5. FAN CONTROL SOLENOID VALVE REPAIR.

Materials/Parts - Continued

Wire, 16 Gage (Item 99, Appendix C)

Contact, Electrical (2) (Item 27, Appendix F)

Dust Boot (2) (Item 29, Appendix F)

Kit, Mounting (Item 86, Appendix F)

Locknut (4) (Item 103, Appendix F)

Packing, Preformed (4) (Item 236, Appendix F)

Packing, Preformed (4) (Item 243, Appendix F)

Packing, Preformed (2) (Item 256, Appendix F)

Splice, Conductor (Item 334, Appendix F)

a. Removal.

The main hydraulic system operates at oil pressures up to 3,675 psi (25,339 kPa). Never

disconnect any hydraulic line, fitting or component without first dropping pressure to zero.

Failure to comply may result in serious injury or death to personnel.

NOTE

• Connectors are removed by gently prying up on tab and pulling connectors apart.

• Cap and plug all hydraulic lines.

• Tag and mark hoses and fittings prior to removal.
TM 9-2320-364-20-5

20-16 

20-5. FAN CONTROL SOLENOID VALVE REPAIR (CONT).

(1) Disconnect MC76 connector (1).

(2) Position drain pan under fan control solenoid valve (2).

NOTE

Fan control solenoid valve may or may not have spacers in Step (3).

(3) Remove four screws (3), spacers (4) and fan control solenoid valve (2) from subplate (5).

(4) Remove four preformed packings (6) from subplate (5). Discard preformed packings.

(5) Remove hoses (7) and (8) and two

preformed packings (9) from adapter (10)

and elbow (11). Discard preformed

packings.

(6) Remove four locknuts (12), screws (13) and

subplate (5) from bracket (14). Discard

locknuts.
TM 9-2320-364-20-5

 20-17

b. Disassembly.

(1) Remove adapter (1), elbow (2) and two

plugs (3) from subplate (4).

(2) Remove four preformed packings (5) from

adapter (1), elbow (2) and two plugs (3).

Discard preformed packings.

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc). 

Failure to comply may result in injury or death to personnel.

(1) Clean all metal parts with drycleaning solvent and dry with compressed air.

(2) Inspect metal parts for breaks, cracks, and sharp edges.

(3) Replace all damaged parts.
TM 9-2320-364-20-5

20-18 

20-5. FAN CONTROL SOLENOID VALVE REPAIR (CONT).

d. Assembly.

(1) Apply hydraulic oil to four preformed

packings (5) and install on adapter (1),

elbow (2) and two plugs (3).

(2) Install adapter (1), elbow (2) and two plugs

(3) on subplate (4).

e. Installation.

(1) Install subplate (5) on bracket (14) using

four screws (13) and locknuts (12). Tighten

to 32 lb-in (3 N.

m).

(2) Apply hydraulic oil to two preformed

packings (9) and install on adapter (10) and

elbow (11).

(3) Install hose (7) on adapter (10) and hose (8)

on elbow (11).
TM 9-2320-364-20-5

 20-19

NOTE

• Perform Steps (4) through

(22) if replacing fan control

solenoid valve and electrical

connector.

• Wires in Step (4) are

fabricated from bulk 16 ga.

wire by 5 in. (12.7 cm) long.

(4) Insert 1 in. (2.5 cm) of two wires (15)

through dust boots (16).

Strip wire after placing it through

dust boot to prevent damage to

individual wire strands.

(5) Strip ends of two wires (15) leaving 1/4 in.

(0.64 cm) of bare wire.

(6) Insert terminal (17) in locating hole of

weatherpac crimper using proper hole

according to the gage of wire (15).

(7) Slide seal (16) down to end of insulation

(18) on wire (15).
TM 9-2320-364-20-5

20-20 

20-5. FAN CONTROL SOLENOID VALVE REPAIR (CONT).

NOTE

Wire and seal should be

positioned so larger wings of

terminal will crimp around dust

boot and smaller wings will crimp

around exposed bare wire.

(8) Position wire (15) on terminal (17).

(9) Press handles of weatherpac crimper

together until ratchet releases and crimp is

complete.

(10) Repeat Steps (6) through (9) for remaining

wire.

(11) Position two terminals (17) and wires (15)

through connector (1) until seated.

(12) Close two secondary locks (19) on

connector (1).

(13) Remove four screws (20), cover (21) and

gasket (22) from fan control solenoid valve

(2). Discard gasket.

(14) Install cord grip (23) on fan control

solenoid valve (2).

(15) Cut and remove two ring terminals (24)

from fan control solenoid valve wires (25).

Discard ring terminals.

23

24

22

21

20

25 2

17

1

19 15
TM 9-2320-364-20-5

 20-21

(16) Install two wires (15) through nut (26),

washer (27), gasket (28), cord grip (23) and

fan control solenoid valve (2).

(17) Position heatshrink (29) on wire (15).

(18) Position ends of wire (15) and fan control

solenoid valve wire (30) in conductor splice

(31) and crimp in place.

(19) Install heatshrink (29) on conductor splice

(31).

(20) Repeat Steps (17) through (19) for

remaining wire.

(21) Install gasket (28), washer (27) and 

nut (26) on cord grip (23).

(22) Install cover (21) and gasket (22) on 

fan control solenoid valve (2) using 

four screws (20).

NOTE

Fan control solenoid valve may or

may not have spacers in Step

(23).

(23) Install fan control solenoid valve (2) on

subplate (5) using four spacers (4) and

screws (3). Tighten to 32 lb-in (3 N.

m).

(24) Apply hydraulic oil to four preformed

packings (6) and install on subplate (5).

(25) Connect MC76 connector (1).

f. Follow-On Maintenance:

• Install Electronic Control Box (ECB), (Para 17-23).

• Start engine. Allow engine to run for three minutes, (TM 9-2320-364-10).

• Shut OFF engine, (TM 9-2320-364-10).

• Check for hydraulic leaks, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

26

27

28

23 2

15

29 31

30

21

22

20
TM 9-2320-364-20-5

20-22 

Materials/Parts

Packing, Preformed (Item 230, Appendix F)

Retainer, Packing (Item 290, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Drain Pan (Item 46, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0-237 N.

m])

(Item 95, Appendix G)

20-6. HIGH PRESSURE HYDRAULIC FILTER REPLACEMENT.

a. Removal.

• Ensure engine is cool before

performing this task or severe

burns from hot hydraulic fluid

may result.

• The main hydraulic system

operates at oil pressures up to

3675 psi (25,339 kPa). Never

disconnect any hydraulic line,

fitting or component without

first dropping pressure to

zero. Failure to comply may

result in serious injury or

death to personnel.

NOTE

Approximately one gallon of oil

will drain from filter and filter

head. A slow trickle of oil will

continue to flow until the 40

gallon reservoir is empty.

(1) Position drain pan under high pressure

hydraulic filter bowl (1).

(2) Loosen hydraulic filter bowl (1).
TM 9-2320-364-20-5

 20-23

Prolonged contact with 

lubricating oil (MIL-L-2104) may

cause a skin rash. Skin and

clothing that come in contact 

with lubricating oil should be

thoroughly washed immediately.

Saturated clothing should be

removed immediately. Areas in

which lubricating oil is used 

should be well-ventilated to keep

fumes to a minimum.

Use care not to damage recessed

groove in filter head when

removing preformed packing.

NOTE

Note shape and position of each

preformed packing during

removal.

(3) Remove hydraulic filter bowl (1), filter

element (2) and preformed packings (3)

and (4) from filter head (5). Discard filter

element and preformed packings.

b. Installation.

NOTE

Install preformed packings as noted prior to removal.

(1) Lubricate preformed packings (3) and (4) with clean hydraulic oil and install in filter head (5).

(2) Install filter element (2) and hydraulic filter bowl (1) on filter head (5) and tighten to 60 lb-ft (81 N.

m).

c. Follow-On Maintenance:

• Check hydraulic fluid level, (TM 9-2320-364-10).

• Start engine, (TM 9-2320-364-10).

• Check hydraulic system for leaks, (TM 9-2320-364-10).

• Shut OFF engine, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

20-24 

Materials/Parts

Lockwasher (4) (Item 168, Appendix F)

Packing, Preformed (Item 234, Appendix F)

Packing, Preformed (Item 252, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

High pressure hydraulic filter removed,

(Para 20-6)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

Wrench, Combination 1 5/8 in.

(Item 84, Appendix G)

Wrench, Torque (0-175 lb-ft [0-257 N.

m])

(Item 95, Appendix G)

20-7. HIGH PRESSURE HYDRAULIC FILTER HEAD ASSEMBLY REPLACEMENT.

a. Removal.

Prolonged contact with 

lubricating oil (MIL-L-2104) may

cause a skin rash. Skin and

clothing that come in contact 

with lubricating oil should be

thoroughly washed immediately.

Saturated clothing should be

removed immediately. Areas in

which lubricating oil is used 

should be well-ventilated to keep

fumes to a minimum.

NOTE

• Tag and mark all hydraulic

hoses prior to removal.

• Cap and plug all hydraulic

hoses to prevent

contamination.

(1) Remove hose 2936 (1) and preformed

packing (2) from elbow (3). Discard

preformed packing.
TM 9-2320-364-20-5

 20-25

(2) Remove hose 2935 (4) and preformed

packing (5) from elbow (6). Discard

preformed packing.

(3) Remove four screws (7), lockwashers (8),

washers (9) and filter head (10) from

bracket (11). Discard lockwashers.

b. Installation.

(1) Install filter head (10), four washers (9),

lockwashers (8) and screws (7) on

bracket (11). Tighten screws to 23 lb-ft

(31 N.

m).

(2) Install hose 2935 (3) and preformed

packing (5) on elbow (6).

(3) Install hose 2936 (1) and preformed

packing (2) on elbow (3).

c. Follow-On Maintenance:

• Install high pressure hydraulic filter, (Para 20-6).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

20-26 

Materials/Parts

Tags, Identification (Item 88, Appendix C)

Packing, Preformed (Item 220, Appendix F)

This task covers:

a. Disassembly c. Assembly

b. Cleaning/Inspection d Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

High pressure hydraulic filter removed,

(Para 20-6)

20-8. HIGH PRESSURE HYDRAULIC FILTER HEAD REPAIR.

Materials/Parts - Continued

Packing, Preformed (2) (Item 234, Appendix F)

Packing, Preformed (Item 249, Appendix F)

Plug (Item 286, Appendix F)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Wrench, Combination 1 5/8 in.

(Item 84, Appendix G)

Wrench, Combination 1 7/8 in.

(Item 87, Appendix G)

a. Disassembly.

(1) Remove plug (1) and preformed

packings (2) and (3) from filter head (4).

Discard plug and preformed packings.

NOTE

Note location and position of

elbows prior to removal.

(2) Loosen jam nut (5) and remove elbow (6)

and preformed packing (7) from filter

head (4). Discard preformed packing.

(3) Loosen jam nut (8) and remove elbow (9)

and preformed packing (10) from filter

head (4). Discard preformed packing.

b. Cleaning/Inspection.

(1) Inspect filter head for cracks and stripped

threads.

(2) Replace all damaged parts.
TM 9-2320-364-20-5

 20-27

c. Assembly.

NOTE

Install elbows in position as noted

prior to removal.

(1) Install preformed packing (10) on elbow (9).

(2) Install elbow (9) in filter head (4). Tighten

jam nut (8).

(3) Install preformed packing (7) on elbow (6).

(4) Install elbow (6) in filter head (4). Tighten

jam nut (5).

(5) Install two preformed packings (2) and (3)

on plug (1).

(6) Install plug (1) in filter head (4).

d. Follow-On Maintenance:

• Install high pressure hydraulic filter, (Para 20-6).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

20-28 

Materials/Parts

Oil, Lubricating (Item 54, Appendix C)

Gasket (Item 46, Appendix F)

Gasket (Item 47, Appendix F)

This task covers:

a. Removal c. Cleaning/Inspection

b. Installation d. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical, Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Torque (0 to 60 N.

m)

(Item 98, Appendix G)

20-9. MAIN HYDRAULIC FILTER REPLACEMENT.
TM 9-2320-364-20-5

 20-29

a. Removal.

Use extreme care when loosening filler cap. Sudden release of pressure could seriously injure 

personnel. Slowly loosen cap to relieve pressure and ensure proper eye protection is worn.

(1) Loosen filler cap (1) and relieve hydraulic pressure in hydraulic reservoir (2).

Ensure area on and around filter cover is clean prior to removal of filter cover to avoid

contamination of hydraulic fluid.

(2) Loosen six screws (3) on filter cover (4).

NOTE

Filter cover is removed from filter base by turning to allow screw heads to pass through large

holes in filter cover.

(3) Remove filter cover (4) from filter base (5).

(4) Remove gasket (6) from filter cover (4). Discard gasket.

Remove hydraulic filter by holding the spring to avoid contamination of hydraulic fluid.

(5) Remove hydraulic filter (7) from filter base (5).
TM 9-2320-364-20-5

20-30 

20-9. MAIN HYDRAULIC FILTER REPLACEMENT (CONT).

NOTE

Relief valve assembly pulls out 

of filter.

(6) Remove spring (8), two preformed

packings (9) and relief valve assembly (10)

from hydraulic filter (7). Discard filter and

preformed packings.

(7) Remove two relief valves (11) from relief

valve assembly (10).

(8) Remove and discard gasket (12) from filter

base (5).

b. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

(1) Clean all metal parts with drycleaning solvent.

Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc).

Failure to comply may result in injury or death to personnel.

(2) Dry metal parts with compressed air.

(3) Inspect metal parts for breaks, cracks and sharp edges.

(4) Manually operate relief valves and inspect for damage.

(5) Replace all damaged parts.
TM 9-2320-364-20-5

 20-31

c. Installation.

Prolonged contact with

lubricating oil (MIL-2104) may

cause a skin rash. Skin and

clothing that come in contact 

with lubricating oil should be

thoroughly washed immediately.

Saturated clothing should be

removed immediately. Areas in

which lubricating oil is used 

should be well-ventilated to keep

fumes to a minimum.

(1) Coat gasket (12) with lubricating oil and

install gasket (12) on filter base. (5).

(2) Install two relief valves (10) in relief valve

assembly (10).

(3) Install relief valve assembly (10) and

spring (8) on hydraulic filter (7).

(4) Coat preformed packings (9) with

lubricating oil and install on hydraulic

filter (7).

(5) Install filter (7) on filter base (5).

Ensure gasket and filter cover are intact before installation. Failure to comply could result in

damage to equipment.

NOTE

Filter cover is installed on filter base by allowing screw heads to pass through large holes in

filter cover and turning filter cover until screw heads are positioned in small holes in filter

cover.

(6) Coat gasket (6) with lubricating oil and install gasket (6) on filter cover (4).

(7) Install filter cover (4) on filter base (5).

(8) Tighten six screws (3) on filter cover (4) to 18 lb-ft (24 N.

m).

(9) Tighten filler cap (1) on hydraulic reservoir (2).

d. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

20-32 

Materials/Parts

Sealing Compound (Item 72, Appendix C)

Lockwasher (4) (Item 168, Appendix F)

Packing, Preformed (Item 245, Appendix F)

Packing, Preformed (Item 252, Appendix F)

This task covers:

a. Removal c. Installation

b. Cleaning/Inspection d. Follow-on Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Hydraulic filter removed, (Para 20-9)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Combination, 1-5/8 in.

(Item 84, Appendix G)

Wrench, Combination, 1-7/8 in.

(Item 87, Appendix G)

Wrench, Pipe 3-1/2 in. Opening

(Item 91, Appendix G)

Wrench, Torque (0 to 60 N.

m)

(Item 98, Appendix G)

20-10. MAIN HYDRAULIC RESERVOIR FILTER ASSEMBLY REPLACEMENT.

a. Removal.

NOTE

• Tag and mark all hydraulic hoses prior to removal.

• Cap and plug all hydraulic hoses to prevent contamination.

(1) Remove hose 2773 (1) and preformed packing (2) from elbow (3). Discard preformed packing.

(2) Remove hose 2918 (4) and preformed packing (5) from adapter (6). Discard preformed packing.

NOTE

Note positions of fittings prior to removal.

(3) Remove elbow (3) and preformed packing (7) from reducer (8). Discard preformed packing.
TM 9-2320-364-20-5

 20-33

(4) Remove reducer (8) and preformed packing

(9) from filter housing (10). Discard

preformed packing.

(5) Remove adapter (6) and preformed packing

(11) from filter housing (10). Discard

preformed packing.

(6) Remove bleeder valve (12) from filter

housing (10).

(7) Remove coupling (13) and preformed

packing (14) from filter housing (10).

(8) Remove four screws (15) and

lockwashers (16) from filter housing (10).

Discard lockwashers.
TM 9-2320-364-20-5

20-34 

20-10. MAIN HYDRAULIC RESERVOIR FILTER ASSEMBLY REPLACEMENT (CONT).

(9) Remove filter housing (10) and gasket (17)

from reservoir (18).

(10) Using a pipe wrench, remove pipe (19)

from filter housing (10).

b. Cleaning/Inspection.

(1) Clean sealing compound from threads.

(2) Clean gasket material from reservoir for

damage.

(3) Inspect filter housing and fittings for cracks,

nicks and stripped threads.

(4) Replace damaged parts.

c. Installation.

NOTE

Install fittings as noted prior to

removal.

(1) Using a pipe wrench, install pipe (19) on

filter housing (10).

(2) Position gasket (17) and filter housing (10)

on hydraulic reservoir (18).
TM 9-2320-364-20-5

 20-35

(3) Install four lockwashers (16) and screws (15)

to filter housing (10) in sequence shown.

Torque screws to 75 to 85 lb-in (9-10 N.

m).

(4) Torque screw (15) in sequence shown to 100

to 110 lb-in (11-12 N.

m).

(5) Install preformed packing (14) and

coupling (13) on filter housing (10).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(6) Apply sealing compound to threads of

bleeder valve (12). Install bleeder valve (12)

in filter housing (10).

(7) Install preformed packing (11) and

adapter (6) in filter housing (10).

(8) Install preformed packing (9) and reducer (8)

in filter housing (10).

(9) Install elbow (3) and preformed packing (7)

on reducer (8).

(10) Install preformed packing (5) and hose

2918 (4) on adapter (6).

(11) Install preformed packing (2) and hose

2773 (1) on elbow (3).

d. Follow-On Maintenance:

• Install main hydraulic filter, (Para 20-9).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

20-36 

Materials/Parts - Continued

Gasket (Item 70, Appendix F)

Packing, Preformed (Item 259, Appendix F)

Screw/Washer (6) (Item 307, Appendix F)

This task covers:

a. Drain b. Fill c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Dispensing Pump (Item 16, Appendix G)

Drum, Storage (Item 21, Appendix G)

Hose, Drain (Item 37, Appendix G)

Pan, Drain (2) (Item 46, Appendix G)

20-11. MAIN HYDRAULIC RESERVOIR SERVICE.

Materials/Parts

Oil, Lubricating (Item 54, Appendix C)

a. Drain.

Prolonged contact with lubricating oil (MIL-L-2104) may cause a skin rash. Skin and

clothing that come in contact with lubricating oil should be thoroughly washed immediately.

Saturated clothing should be removed immediately. Areas in which lubricating oil is used

should be well-ventilated to keep fumes to a minimum.

Clean area before removing filler breather to keep foreign matter out of hydraulic reservoir

and to prevent damage.

NOTE

• Perform Steps (1) through (5) if truck is not equipped with hydraulic drain hose.

• Perform Steps (6) through (10) if truck is equipped with hydraulic drain hose.
TM 9-2320-364-20-5

 20-37

(1) Remove cap (1), six screw and washer

assemblies (2), strainer (3), and gasket (4)

from hydraulic reservoir (5). Discard

gasket and screw and washer assemblies.

(2) Remove preformed packing (6) from 

cap (1). Discard preformed packing.

(3) Position dispensing pump in hydraulic

reservoir (5).

(4) Pump oil into storage drum.

(5) Remove dispensing pump from hydraulic

reservoir (5).

(6) Remove cap (1) from hydraulic reservoir (5).

(7) Remove hydraulic drain hose (7) from

bracket (8).

(8) Remove tethered cap (9) and position

hydraulic drain hose over storage drum.

(9) Open valve (10) and drain oil into storage

drum.

(10) Close valve (10), install tethered cap (9) and

position hydraulic drain hose (7) into

bracket (8).

(11) Position drain pan under plug (11).

(12) Remove plug (11) from hydraulic reservoir

(5) and drain excess oil.

(13) Remove and discard preformed packing

(12) from plug (11).

11 12

5
TM 9-2320-364-20-5

20-38 

20-11. MAIN HYDRAULIC RESERVOIR SERVICE (CONT).

(14) Apply lubricating oil to preformed packing

(12) and install on plug (11).

(15) Install plug (11) in hydraulic reservoir (5).

NOTE

Perform Steps (16) and (17) if

preformed packing, gasket, and

strainer were removed.

(16) Apply lubricating oil to preformed packing

(6) and install on cap (1).

(17) Install gasket (4) and strainer (3) on

hydraulic reservoir (5) with six screw and

washer assemblies (2). Tighten screws to

10 to 15 lb-in (1 to 2 N.

m).

(18) Install cap (1) on strainer (3).
TM 9-2320-364-20-5

 20-39

b. Fill.

Prolonged contact with

lubricating oil (MIL-L-2104) may

cause a skin rash. Skin and

clothing that come in contact with

lubricating oil should be

thoroughly washed immediately.

Saturated clothing should be

removed immediately. Areas in

which lubricating oil is used

should be well-ventilated to keep

fumes to a minimum.

NOTE

Ensure all auxiliary equipment is

stowed otherwise reservoir can 

be overfilled.

(1) Remove filler breather cap (1) from

reservoir (5).

Cold hydraulic oil expands when

hot. Do not fill reservoir past the

word full on fluid level indicator.

Failure to comply may result in

damage to equipment.

(2) Fill hydraulic reservoir (5) with lubricating

oil (MIL-L-2104) until fluid level indicator (6)

points to the word full.

(3) Install filler breather cap (1) on 

reservoir (5).

c. Follow-On Maintenance:

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

6

COLD FILL MAXIMUM
TM 9-2320-364-20-5

20-40 

Materials/Parts

Cable Ties (Item 25, Appendix C)

Tags, Identification (Item 88, Appendix C)

Locknut (Item 96, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Spare tire carrier and davit removed, (Para 15-21)

Electronic control box (ECB), (Right

side panel removed), (Para 17-21)

Right side noise panel removed, (Para 17-26)

Right fender front skirt removed, (Para 17-33)

Cab engine access panel removed, (Para 17-24)

Main hydraulic reservoir drained, (Para 20-11)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Wrench, Crowsfoot 3/4 in. (3/8 Drive)

(Item 34, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Combination 1 1/8 in.

(Item 79, Appendix G)

Wrench, Combination 1 5/8 in.

(Item 84, Appendix G)

Wrench, Combination 1 7/8 in.

(Item 87, Appendix G)

Wrench, Combination 2 1/8 in.

(Item 89, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0-237 N.

m])

(Item 95, Appendix G)

Wrench, Torque (0 to 60 N.

m)

(Item 98, Appendix G)

Lifting Device, Minimum Capacity 200 lbs.

(91 kg)

20-12. MAIN HYDRAULIC RESERVOIR REPLACEMENT.

Materials/Parts - Continued

Locknut (3) (Item 106, Appendix F)

Lockwasher (3) (Item 180, Appendix F)

Lockwasher (3) (Item 195, Appendix F)

Packing, Preformed (Item 226, Appendix F)

Packing, Preformed (Item 233, Appendix F)

Packing, Preformed (Item 236, Appendix F)

Packing, Preformed (2) (Item 237, Appendix F)

Packing, Preformed (Item 245, Appendix F)

Packing, Preformed (Item 251, Appendix F)

Packing, Preformed (Item 252, Appendix F)

Packing, Preformed (3) (Item 227, Appendix F)

Packing, Preformed (Item 244, Appendix F)

Pin, Cotter (2) (Item 265, Appendix F)
TM 9-2320-364-20-5

 20-41

a. Removal.

Prolonged contact with lubricating oil (MIL-L-2104) may cause a skin rash. Skin and clothing

that come in contact with lubricating oil should be thoroughly washed immediately. Saturated

clothing should be removed immediately. Areas in which lubricating oil is used should be

well-ventilated to keep fumes to a minimum.

NOTE

• Tag and mark all hydraulic hoses prior to removal.

• Cap and plug all hydraulic hoses to prevent contamination.

• Remove cable ties as required.

(1) Remove hose 2918 (1) and preformed packing (2) from fitting (3). Discard preformed packing.

NOTE

Connector is removed by gently prying on tab and pulling connectors apart.

(2) Disconnect connector (4) from fluid level gage (5).
TM 9-2320-364-20-5

20-42 

20-12. MAIN HYDRAULIC RESERVOIR REPLACEMENT (CONT).

(3) Remove locknut (6), screw (7) and clip (8)

from bracket (9) and hose 2773 (10).

Discard locknut.

(4) Remove hose 2773 (10) and preformed

packing (11) from elbow (12). Discard

preformed packing.

(5) Remove cotter pin (13) from retaining

pin (14). Discard cotter pin.

(6) Remove retaining pin (14) from clevis (15)

and bracket (16).
TM 9-2320-364-20-5

 20-43

(7) Remove four screws (17), lockwashers (18), two split flanges (19), hose 2498 (20) and preformed

packing (21) from hydraulic reservoir (22). Discard lockwashers and preformed packing.

(8) Remove hose 2781 (23) and preformed packing (24) from tee (25). Discard preformed packing.
TM 9-2320-364-20-5

20-44 

20-12. MAIN HYDRAULIC RESERVOIR REPLACEMENT (CONT).

NOTE

If vehicle is equipped with crane, perform Step (9).

(9) Remove hose 2694 (26) and preformed packing (27) from elbow (28) on hydraulic reservoir (22). 

Discard preformed packing.
TM 9-2320-364-20-5

 20-45

(10) Remove three locknuts (29) and screws (30)

from hydraulic reservoir (22). Discard

locknuts.

(11) Remove locknut (31) and screw (32) from

hydraulic reservoir (22). Discard locknut.

Hydraulic reservoir weighs 

120 lbs (54 kg). The aid of an

assistant is required to prevent

possible injury to personnel.

Use caution when removing

hydraulic reservoir. Hose on the

rear of reservoir may be damaged

if caution is not taken.

(12) With the aid of an assistant, remove

hydraulic reservoir (22) from fender (33).

(13) Remove screw (34), lockwasher (35),

washer (36) and clip bracket (37) from

hydraulic reservoir (22). Discard

lockwasher.

(14) Remove two screws (38), lockwashers (39)

and plate (40) from hydraulic reservoir (22).

Discard lockwashers.

(15) Remove cotter pin (41), clevis pin (42) and

clevis (43) from plate (40). Discard cotter

pin.
TM 9-2320-364-20-5

20-46 

20-12. MAIN HYDRAULIC RESERVOIR REPLACEMENT (CONT).

NOTE

• Perform Steps (16) through

(20) if truck is equipped

with hydraulic drain hose

assembly.

• Perform Steps (21) and (22)

if truck is not equipped with

hydraulic drain hose

assembly.

(16) Remove hose 2781 (44) and preformed

packing (45) from adapter (46). Discard

preformed packing.

(17) Remove hydraulic drain hose (47), and

preformed packing (48) from tee (49).

Discard preformed packing.

(18) Remove adapter (46) and preformed

packing (50) from tee (49). Discard

preformed packing.

(19) Remove tee (49) and preformed packing

(51) from hydraulic reservoir (22). Discard

preformed packing.

(20) Remove tethered cap (52), adapter (53),

valve (54), adapter (55), and preformed

packing (56) from hydraulic drain hose

(47). Discard preformed packing.

(21) Remove hose 2781 (23) and preformed

packing (57) from elbow (58). Discard

preformed packing.

NOTE

Note position of fittings before

removal.

(22) Loosen backer nut (59) and remove

elbow (58) and preformed packing (60)

from hydraulic reservoir (22). Discard

preformed packing.

48

23

52

49

51

60

22

44

55

56

53 54

47

50

46

45

58

59

57
TM 9-2320-364-20-5

 20-47

NOTE

• Perform Step (23) if truck is

equipped with a crane.

• Perform Step (24) is truck is

not equipped with a crane.

(23) Loosen backer nut (61) and remove

elbow (28) and preformed packing (62)

from hydraulic reservoir (22). Discard

preformed packing.

(24) Remove plug (63) and preformed

packing (64) from hydraulic reservoir (22).

Discard preformed packing.

(25) Remove plug (65) and preformed

packing (66) from hydraulic reservoir (22).

Discard preformed packing.

b. Installation.

(1) Install preformed packing (66) and plug (65)

in hydraulic reservoir (22).

NOTE

• Perform Step (2) if truck is

not equipped with a crane.

• Perform Step (3) if truck is

equipped with crane.

(2) Install preformed packing (64) and plug (63)

on hydraulic reservoir (22).

(3) Install preformed packing (62) and

elbow (28) in hydraulic reservoir (22) and

tighten backer nut (61).
TM 9-2320-364-20-5

20-48 

20-12. MAIN HYDRAULIC RESERVOIR REPLACEMENT (CONT).

NOTE

• Perform Steps (4) and (5) if

truck is not equipped with

hydraulic drain hose

assembly.

• Perform Steps (6) through

(10) if truck is equipped

with hydraulic drain hose

assembly.

(4) Install preformed packing (60) and

elbow (58) in hydraulic reservoir (22) and

tighten backer nut (59).

(5) Install preformed packing (57) and hose

2781 (23) on elbow (58).

(6) Install preformed packing (51) and tee (49)

on hydraulic reservoir (22).

(7) Install preformed packing (56), adapter (55),

valve (54), adapter (53) and tethered cap

(52) on hydraulic drain hose (47).

(8) Install preformed packing (50) and adapter

(46) on tee (49).

(9) Install preformed packing (48) and hydraulic

drain hose (47) on tee (49).

(10) Install preformed packing (45) and hose

2781 (44) on adapter (46).

48

23

52

49

51

60

22

44

55

56

53 54

47

50

46

45

58

59

57
TM 9-2320-364-20-5

 20-49

(11) Install clevis (43), clevis pin (42) and cotter

pin (41) on plate (40).

(12) Install plate (40) on hydraulic reservoir (22)

with two lockwashers (39) and screws (38).

(13) Install clip bracket (37), flat washer (36),

lockwasher (35) and screw (34) on

hydraulic reservoir (22).

Hydraulic reservoir weighs 120

lbs (54 kg). Use the aid of an

assistant to install to prevent

injury to personnel.

Use caution when installing

hydraulic reservoir. Hose on the

rear of reservoir may be 

damaged if caution is not taken.

(14) With the aid of an assistant, position

hydraulic reservoir (22) on fender (33).

(15) Install screw (32) and locknut (31) on

hydraulic reservoir (22). Tighten locknut to

90 lb-ft (122 N.

m).

(16) Install three screws (30) and locknuts (29)

on hydraulic reservoir (22). Tighten

locknuts to 45 lb-ft (61 N.

m).
TM 9-2320-364-20-5

20-50 

20-12. MAIN HYDRAULIC RESERVOIR REPLACEMENT (CONT).

NOTE

Perform Step (12) only if vehicle is equipped with a crane.

(17) Install preformed packing (27) and hose 2694 (26) on elbow (28) on hydraulic reservoir (22).

(18) Install preformed packing (24) and hose

2781 (23) on tee (25).
TM 9-2320-364-20-5

 20-51

Ensure hose 2498 has minimum

of two inches (5 cm) of clearance

from cab upon installation.

Failure to comply may result in

damage to hose.

(19) With the aid of an assistant, install

preformed packing (21), hose 2498 (20),

two split flanges (19), four lockwashers

(18) and screws (17) on hydraulic reservoir

(22). Tighten screws to 30 lb-ft (41 N.

m).

(20) Install yoke (15) on bracket (16) with

retainer pin (14).

(21) Install cotter pin (13) in retaining pin (14).

(22) Install preformed packing (11) and hose

2773 (10) on elbow (12).

Ensure clip is mounted in top 

hole of bracket only. Failure to

comply may result in damage to

hose 2773.

(23) Install clip (8), screw (7) and locknut (6) on

bracket (9) and hose 2773 (10).
TM 9-2320-364-20-5

20-52 

20-12. MAIN HYDRAULIC RESERVOIR REPLACEMENT (CONT).

(24) Connect connector (4) on fluid level

gage (5).

(25) Install preformed packing (2) and hose

2918 (1) on fitting (3).

c. Follow-On Maintenance:

• Fill main hydraulic reservoir, (Para 20-11).

• Start engine and allow to idle for five minutes, (TM 9-2320-364-10).

• Shut off engine and check for hydraulic leaks, (TM 9-2320-364-10).

• Install cab engine access panel, (Para 17-24).

• Install right fender front skirt, (Para 17-33).

• Install right side noise panel, (Para 17-26).

• Install Electronic Control Box (ECB), right side panel, (Para 17-21).

• Install spare tire carrier and davit, (Para 15-21).

• Install spare tire, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 20-53

Materials/Parts

Gasket (Item 51, Appendix F)

Lockwasher (27) (Item 180, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Hydraulic reservoir drained, (Para 20-11)

Fluid level gage removed, (Para 20-15)

Main hydraulic reservoir filter assembly removed,

(Para 20-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Strainer Tool (Item 65, Appendix G)

Wrench, Pipe 3 1/2 in. Opening

(Item 91, Appendix G)

Wrench, Torque (0 to 60 N.

m)

(Item 98, Appendix G)

20-13. HYDRAULIC RESERVOIR STRAINER REPLACEMENT.

a. Removal.

Prolonged contact with lubricating oil (MIL-L-2104) may cause a skin rash. Skin and clothing

that come in contact with lubricating oil should be thoroughly washed immediately. Saturated

clothing should be removed immediately. Areas in which lubricating oil is used should be

well-ventilated to keep fumes to a minimum.

NOTE

Note position of bracket prior to removal.

(1) Remove screw (1), lockwasher (2), washer (3) and bracket (4) from reservoir bracket (5). Discard

lockwasher.

(2) Remove 26 screws (6) and lockwashers (7) from lid (8). Discard lockwashers.

(3) Remove lid (8) and gasket (9) from hydraulic reservoir (10). Discard gasket.
TM 9-2320-364-20-5

20-54 

20-13. HYDRAULIC RESERVOIR STRAINER REPLACEMENT (CONT).

(4) Using strainer tool, remove strainer (11) and

nipple (12) from hydraulic reservoir (10).

(5) Remove nipple (12) from strainer (11).

b. Installation.

(1) Install nipple (12) on strainer (11).

(2) Using strainer tool, install nipple (12) and

strainer (11) in hydraulic reservoir (10).

(3) Position gasket (9) and lid (8) on hydraulic reservoir (10).

(4) Install lid (8) with 26 lockwashers (7) and screws (6). Tighten screws to 45 to 65 lb-in (5-7 N.

m) using

torque sequence as shown. Repeat torque sequence and torque to 60 to 65 lb-in (7 N.

m).

NOTE

Install bracket in position as noted prior to removal.

(5) Install bracket (4), washer (3), lockwasher (2) and screw (1) on reservoir bracket (5). Tighten screw to 45

to 65 lb-in (5-7 N.

m).
TM 9-2320-364-20-5

 20-55

c. Follow-On Maintenance:

• Install main hydraulic reservoir filter assembly, (Para 20-10).

• Install fluid level gage, (Para 20-15).

• Fill hydraulic reservoir, (Para 20-11).

• Check for oil leaks, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

20-56 

Materials/Parts

Oil, Lubricating (Item 54, Appendix C)

Gasket, (Item 70, Appendix F)

Packing, Preformed (Item 259, Appendix F)

Screw/Washer Assembly (6)

(Item 307, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

20-14. HYDRAULIC RESERVOIR FILLER BREATHER REPLACEMENT.

a. Removal.

Clean area before removing 

filler breather to keep foreign

matter out of hydraulic reservoir

and to prevent damage.

(1) Remove cap (1), six screw and washer

assemblies (2), strainer (3) and gasket (4)

from hydraulic reservoir (5). Discard gasket

and screw and washer assemblies.

After filler breather is removed,

cover opening to keep foreign

matter out of hydraulic reservoir

and to prevent possible damage.

(2) Cover opening on hydraulic reservoir (5).

(3) Remove chain (6) from cap (1).

(4) Remove preformed packing (7) from cap (1).

Discard preformed packing.
TM 9-2320-364-20-5

 20-57

b. Installation.

(1) Remove cover from opening on hydraulic

reservoir (5).

(2) Apply lubricating oil to preformed packing

(7) and install on cap (1).

(3) Install chain (6) on cap (1).

(4) Position gasket (4) and strainer (3) on

hydraulic reservoir (5) with six screw and

washer assemblies (2).

(5) Tighten screws (2) down evenly until screw

heads contact strainer top (3).

(6) Tighten each screw (2) one full turn.

(7) Install cap (1) on strainer (3).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

20-58 

Materials/Parts

Lockwasher (4) (Item 195, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/8 in (Item 62, Appendix G)

Wrench, Torque (0 to 60 N.

m)

(Item 98, Appendix G)

20-15. HYDRAULIC FLUID LEVEL GAGE REPLACEMENT.

a. Removal.

NOTE

Connector is removed by gently

prying on tab and pulling

connectors apart.

(1) Disconnect connector (1) from fluid level

gage (2).

(2) Remove four screws (3) and lockwashers (4)

from fluid level gage (2). Discard

lockwashers.

Handle fluid level gage with care

to avoid damage to gage.

(3) Remove fluid level gage (2) from hydraulic

reservoir (5).

After fluid level gage is removed,

cover opening to keep foreign

matter out of hydraulic reservoir

and to prevent possible damage.

(4) Cover opening of hydraulic reservoir (5).
TM 9-2320-364-20-5

 20-59

b. Installation.

Handle fluid level gage with care

to avoid damage to gage.

(1) Remove cover from opening on hydraulic

reservoir (5).

(2) Install fluid level gage (2) on hydraulic

reservoir (5) with four lockwashers (4) and

screws (3). Tighten screws to 35 to 43 lb-in

(4-5 N.

m).

(3) Connect connector (1) on fluid level

gage (2).

c. Follow-On Maintenance:

• Check gage operation, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

20-60 

This task covers:

a. Installation b. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Spare tire removed, (TM 9-2320-364-10)

Right side noise panel removed, (Para 17-26)

Main hydraulic reservoir drained, (Para 20-11)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Combination 1 1/8 in.

(Item 79, Appendix G)

Wrench, Combination 1 5/8 in.

(Item 84, Appendix G)

Wrench, Combination 1 7/8 in.

(Item 87, Appendix G)

Wrench, Combination 2 1/8 in.

(Item 89, Appendix G)

20-16. HYDRAULIC DRAIN HOSE KIT INSTALLATION.

Materials/Parts

Locknut (Item 91, Appendix F)

a. Installation.

(1) Remove locknut (1) and screw (2) from tire

carrier (3) and fender assembly (4). Discard

locknut.

(2) Install hydraulic drain hose bracket (5) with

screw (2) and locknut (1) on fender (4).

1

4

3

2

2

5

1

4
TM 9-2320-364-20-5

 20-61

(3) Follow diagram to cut opening in right side noise panel (6).

(4) Install molding (7) on right side noise panel (6).

2.375 IN.

(6.03 CM)

4.5 IN.

(11.43 CM)

7

6

8 IN.

(30.32 CM)
TM 9-2320-364-20-5

20-62 

20-16. HYDRAULIC DRAIN HOSE KIT INSTALLATION (CONT).

(5) Remove hose 2781 (8) and preformed

packing (9) from elbow (10). Discard

preformed packing.

NOTE

Note position of fitting before

removal.

(6) Loosen backer nut (11) and remove elbow

(10) and preformed packing (12) from

hydraulic reservoir (13). Discard elbow and

preformed packing.

(7) Install preformed packing (14), adapter (15),

valve (16), adapter (17) and tethered cap

(18) on hydraulic drain hose (19).

(8) Install preformed packing (20) and tee (21)

on hydraulic reservoir (13).

(9) Install preformed packing (22) and hydraulic

drain hose (19) on tee (21).

(10) Install preformed packing (23) and adapter

(24) on tee (21).

(11) Install preformed packing (25) and hose

2781 (8) on adapter (24).

20

11

21

8

24

12

10

23

22

16

8

18

9

15

19

17

14

25

13
TM 9-2320-364-20-5

 20-63/(20-64 blank)

(12) Position hydraulic drain hose (19) onto

hydraulic drain hose bracket (8).

b. Follow-On Maintenance:

• Fill main hydraulic reservoir, (Para 20-11).

• Start engine and allow to idle for five minutes, (TM 9-2320-364-10).

• Shut off engine and check for hydraulic leaks, (TM 9-2320-364-10).

• Install right side noise panel, (Para 17-26).

• Install spare tire, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

19

8

TM 9-2320-364-20-5

 21-1

CHAPTER 21

SPECIAL PURPOSE KITS MAINTENANCE

Para Contents Page

21-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1

21-2 Arctic Kit Relays Replacement 21-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-3 Arctic Pump Switch Replacement 21-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-4 Arctic Kit Battery Replacement 21-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-5 Arctic Kit Battery Box Replacement 21-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-6 Arctic Kit Water Pump Replacement 21-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-7 Arctic Kit Waterjacket Replacement 21-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-8 Arctic Kit Wire Harness Replacement 21-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-9 Arctic Kit Jumperwire Harness Replacement 21-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-10 Arctic Kit Switch Wire Harness Replacement 21-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-11 Arctic Kit Battery Disconnection/Connection 21-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-12 Interface Quick Disconnect Assembly Replacement 21-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-13 Interface Mounting Bracket Replacement 21-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-14 Interface Wiring Harness Replacement 21-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-15 Interface Powerbox Assembly Repair 21-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-16 Interface Powerbox Wiring Replacement 21-71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-17 Interface Auxiliary Hydraulic Valve Replacement 21-76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-18 Interface Manaul Override Solenoid Valve Replacement 21-79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-19 Container Handling Unit (CHU) Jumperwire Harness Replacement 21-82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-20 Container Handling Unit (CHU) Wire Harness Replacement 21-84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-21 Container Handling Unit (CHU) Control Box Assembly Replacement 21-88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-22 Container Handling Unit (CHU) Control Box Wiring Replacement 21-91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-23 Container Handling Unit (CHU) Control Box Repair 21-95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-24 Container Handling Unit (CHU) Proximity Switch And Sensing Plate

Replacement/Adjustment (Hook Arm Up) 21-97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-25 Container Handling Unit (CHU) Mode Switch Replacement/Adjustment 21-104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-26 Container Handling Unit (CHU) Rear Lock Limit Switch Replacement/Adjustment 21-108 . . . . . . . . . . . . . . . 

21-27 Container Handling Unit (CHU) Light Bar And Brackets Assembly Repair 21-114 . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-28 Container Handling Unit (CHU) Container Guide Repair 21-123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-29 Container Handling Unit (CHU) Slider/Pivot Assembly Repair 21-127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-30 Container Handling Unit (CHU) Short Strut And Pin Bracket Assembly Repair 21-137 . . . . . . . . . . . . . . . . . . . . . 

21-31 Container Handling Unit (CHU) Slider Arm Assembly Repair 21-144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-32 Container Handling Unit (CHU) Rear Bracket Assembly Replacement 21-152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-33 Container Handling Unit (CHU) Long Strut Bracket Assembly Repair 21-158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-34 Container Handling Unit (CHU) Stow Weldment Replacement 21-168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-35 Container Handling Unit (CHU) Lifting Frame Assembly Replacement 21-175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-36 Container Handling Unit (CHU) Lifting Frame Locking Plate Assembly Replacement 21-186 . . . . . . . . . . . 

21-37 Container Handling Unit (CHU) Lifting Frame Lower Container Lock Plate Repair 21-188 . . . . . . . . . . . . . . . 

21-38 Container Handling Unit (CHU) Lifting Frame Flipper Bracket And Lock Plate Repair 21-192 . . . . . . . . . . 

21-39 Self-Recovery Winch (SRW) Container Handling Unit (CHU) Rear Guide Replacement 21-201 . . . . . . . . 

21-40 Container Handling Unit (CHU) Deck Weldment Replacement 21-203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-41 Container Handling Unit (CHU) Bumper Weldment Support Replacement 21-205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-42 Container Handling Unit (CHU) Air Valve Replacement 21-210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-43 Container Handling Unit (CHU) Air Cylinder And Rotary Paddle Replacement/Adjustment 21-213 . . . 

21-44 Container Handling Unit (CHU) Stow Cone Weldment Replacement 21-220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-45 Container Handling Unit (CHU) Front Crossmember Assembly Replacement 21-223 . . . . . . . . . . . . . . . . . . . . . . . 

21-46 Container Handling Unit (CHU) Front Support Brackets Replacement 21-225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-47 Container Handling Unit (CHU) Lifting Frame Strap Replacement 21-231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21-1. INTRODUCTION.

This chapter contains maintenance instructions for removing, replacing, installing and adjusting components of the

special purpose kits as authorized by the Maintenance Allocation Chart (MAC) at the Unit Maintenance level.
TM 9-2320-364-20-5

21-2 

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

21-2. ARCTIC KIT RELAYS REPLACEMENT.

a. Removal.

(1) Remove eight screws (1) and heater compartment access panel (2) from heater compartment (3).

(2) Remove four screws (4) from front heater

panel (5) and tilt front heater panel forward

away from heater compartment (3).
TM 9-2320-364-20-5

 21-3

NOTE

These are two 24V relays. Both

relays are removed and installed

the same way. Refer to electrical

schematic for identification of

relays.

(3) Remove two arctic relays (6) from relay

sockets (7).

b. Installation.

(1) Install two arctic relays (6) on relay

sockets (7).

(2) Install front heater panel (5) on heater

compartment (3) with four screws (4).

(3) Install heater compartment access panel (2)

on heater compartment (3) with eight

screws (1).

c. Follow-On Maintenance:

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

21-4 

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Heater compartment cover removed,

(Para 17-4)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

21-3. ARCTIC PUMP SWITCH REPLACEMENT.

a. Removal.

(1) Remove three screws (1) from Electronic Control Box (ECB) cover (2).

(2) Remove four screws (3) from front heater panel (4).

(3) Tilt front heater panel (4) forward away from heater box (5).

(4) Disconnect S29 connector (6) from arctic pump switch (7).

(5) Disconnect arctic pump switch light connector (8) from arctic pump switch (7).

NOTE

Switch is removed by compressing retaining tabs.

(6) Remove arctic pump switch (7) from heater panel (4).

(7) Remove light plug (9) from arctic pump switch (7).

(8) Remove applique (10) from arctic pump switch (7).
TM 9-2320-364-20-5

 21-5

b. Installation.

(1) Install applique (10) in arctic pump

switch (7).

(2) Install light plug (9) in rear of arctic pump

switch (7).

(3) Install arctic pump switch (7) in heater

panel (4).

(4) Connect arctic pump switch light

connector (8) to arctic pump switch (7).

(5) Connect S29 connector (6) to arctic pump

switch (7).

(6) Tilt heater panel (4) back against heater

box (5).

(7) Install four screws (3) in heater panel (4).

(8) Install three screws (1) in ECB cover (2).

c. Follow-On Maintenance:

• Install heater compartment cover, (Para 17-4).

• Connect batteries, (Para 7-87).

• Check operation of arctic pump switch, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

21-6 

Materials/Parts

Coating Compound, Bituminous Solvent Type

(Item 32, Appendix C)

Locknut (4) (Item 114, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Arctic kit batteries disconnected (if equipped),

(Para 21-11)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

21-4. ARCTIC KIT BATTERY REPLACEMENT.

a. Removal.

• Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and rubber

gloves, and do not smoke when performing maintenance on batteries. Injury will result if

acid contacts skin or eyes. Wear rubber apron to prevent clothing being damaged.

• Remove all jewelry such as rings, dog tags, bracelets, etc. If jewelry or tools contact

positive electrical circuits a direct short may result. Damage to equipment, injury or death

to personnel may occur.

NOTE

Both batteries are removed the

same way.

(1) Remove four locknuts (1), washers (2) two

hold down straps (3) and four carrier

screws (4) from batteries (5) and battery

box (6). Discard locknuts.

Battery weighs 75 lbs (34 kg).

Remove battery only with the aid

of an assistant to prevent possible

injury to personnel.

(2) With the aid of an assistant, remove two

batteries (5) from battery box (6).
TM 9-2320-364-20-5

 21-7

b. Installation.

Battery weighs 75 lbs (34 kg).

Install battery only with the aid of

an assistant to prevent possible

injury to personnel.

NOTE

Refer to TM 9-6140-200-14 for

more specific details on battery

maintenance.

(1) With the aid of an assistant, position two

batteries (5) in battery box (6).

(2) Install two hold down straps (3) and four

carrier screws (4) with two washers (2) and

locknuts (1) in battery box (6).

Corrosion inhibitor contains alkali. Do not get in eyes; wear goggles/safety glasses when

using. Avoid contact with skin. In case of contact, immediately wash area with soap and

water. If eyes are contacted, flush eyes with large amounts of water for at least 15 minutes

and get immediate medical attention.

(3) Coat threads of four carrier screws (4), washers (2), and lock nuts (1) with bituminous.

c. Follow-On Maintenance:

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

21-8 

Materials/Parts

Locknut (4) (Item 106, Appendix F)

Locknut (18) (Item 140, Appendix F)

Lockwasher (2) (Item 168, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine off, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Arctic kit batteries removed, (Para 21-4)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

21-5. ARCTIC KIT BATTERY BOX REPLACEMENT.

a. Removal.

(1) Remove nut (1), lockwasher (2), two washers (3), screw (4) and positive battery post terminal (5) from

battery cable 1139 (6). Discard lockwasher.

(2) Remove nut (7), lockwasher (8), two washers (9), screw (10) and negative battery post terminal (11) from

battery cable 1137 (12). Discard lockwasher.

4

10

5

6

3

2

1

9

11 12

9

8

7

3
TM 9-2320-364-20-5

 21-9

(3) Remove locknut (13), screw (14) and

cushion clamp (15) from rear of battery

box (16). Discard locknut.

(4) Remove locknut (17), screw (18) and two

cushion clamps (19) from battery tray (20).

Discard locknut.

(5) Remove two rubber grommets (21) and

battery cables 1139 (6) and 1137 (12)

through battery box (16).

(6) With the aid of an assistant, remove two

locknuts (22) and screws (23) from battery

tray (20). Discard locknuts.

Battery box weighs 75 lbs (34

kg). Use the aid of an assistant 

to prevent possible injury to

personnel.

(7) With the aid of an assistant, remove battery

box (16) from left fender (24).

(8) Remove four locknuts (25), screws (26) and

left and right guides (27) from left

fender (24).

b. Installation.

(1) Install left and right guides (27) on left

fender (24) with four screws (26) and

locknuts (25).
TM 9-2320-364-20-5

21-10 

21-5. ARCTIC KIT BATTERY BOX REPLACEMENT (CONT).

Battery box weighs 75 lbs (34 kg). Use the aid of an assistant to prevent possible injury to

personnel.

(2) With the aid of an assistant, position battery box (16) on left fender (24).

(3) With the aid of an assistant, install battery tray (20) through left and right guides (27).

(4) Install two screws (23) and locknuts (22) to battery tray (20).

(5) Install two rubber grommets (21) on two

battery cables (6) and (12).

(6) Install two battery cables (6) and (12) and

rubber grommets (21) in battery box (16).

(7) Install two cushion clamps (19) on rear of

battery box tray (20) with screw (18) and

locknut (17).

(8) Install cushion clamp (15) on rear of battery

box (16) with screw (14) and locknut (13).
TM 9-2320-364-20-5

 21-11

(9) Install negative battery post terminal (11) on

battery cable 1137 (12) with screw (10), two

washers (9), lockwasher (8) and nut (7).

While applying torque to nut,

hold screw with wrench or

damage to battery may occur.

(10) Tighten nut (7) to 12 to 16 lb-ft (16-22

N.

m).

(11) Install positive battery post terminal (5) on

battery cable 1139 (6) with screw (4), two

washers (3), lockwasher (2) and nut (1).

While applying torque to nut,

hold screw with wrench or

damage to battery may occur.

(12) Tighten nut (1) to 12 to 16 lb-ft (16-22

N.

m).

c. Follow-On Maintenance:

• Install arctic kit batteries, (Para 21-4).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

4

10

5

6

3

2

1

9

11 12

9

8

7

3
TM 9-2320-364-20-5

21-12 

Materials/Parts

Adhesive (Item 2, Appendix C)

Sealing Compound (Item 72, Appendix C)

Tags, Identification (Item 88, Appendix C)

Locknut (2) (Item 96, Appendix F)

Locknut (Item 140, Appendix F)

Lockwasher (22) (Item 195, Appendix F)

Rubber Pads (Item 292, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Pan, Drain (Item 47, Appendix G)

Wrench, Combination, 1 1/8 in.

(Item 79, Appendix G)

Wrench, Torque (0-60 N.

m)

(Item 98, Appendix G)

21-6. ARCTIC KIT WATER PUMP REPLACEMENT.

a. Removal.

Do not remove hoses when cooling system is hot; steam and hot coolant can escape and burn

personnel.

(1) Remove 22 screws (1), lockwashers (2), washers (3) and cab engine access panel (4) from cab (5).
TM 9-2320-364-20-5

 21-13

(2) Shut off ball valve (6).

(3) Remove eight screws (7) and left side noise panel (8).
TM 9-2320-364-20-5

21-14 

21-6. ARCTIC KIT WATER PUMP REPLACEMENT (CONT).

(4) Shut off ball valve (9).

(5) Twist handle (10) and open front access cover (11).

(6) Position drain pan under truck.

(7) Loosen clamp (12) and slide up on hose (13).

(8) Remove hose (13) from fitting (14).

(9) Loosen clamp (15) on hose (16).
TM 9-2320-364-20-5

 21-15

(10) Remove two locknuts (17) and screws (18)

from clamping bracket (19) and bracket

(20). Discard locknuts.

(11) Remove bracket (19) and rubber pads (21)

from water pump (22). Discard rubber pad.

(12) Matchmark water pump (22) and bracket

(20).

(13) Rotate water pump (22) to the left and

remove hose (16) from fitting (23).

(14) Remove nut (24) and screw (25) from

bracket (26) and bracket (20).

(15) Pull out water pump (22) until wire 1435

(27) and wire 1644 (28) are exposed.

NOTE

Tag and mark all wires upon

removal.

(16) Remove nut (29) and wire 1435 (27) from

water pump (22).

(17) Remove nut (29) and wire 1644 (28) from

water pump (22).

(18) Remove water pump (22) from bracket

(20).

(19) Remove fittings (14) and (23) from water

pump (22).
TM 9-2320-364-20-5

21-16 

21-6. ARCTIC KIT WATER PUMP REPLACEMENT (CONT).

(20) Remove two locknuts (31), screws (32),

retaining plate (33) and bracket (20) from

cab (5).

(21) Remove rubber pad (26) from bracket (20).

Discard rubber pad.

b. Installation.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in well

ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(1) Apply adhesive to rubber pad (26) and

install rubber pad on bracket (20).

(2) Install bracket (20) and retaining plate (33)

in cab (5) with two screws (32) and locknuts

(31).

(3) Coat threads of fittings (14) and (23) with

sealing compound.

(4) Install fittings (14) and (23) in water 

pump (22).

20

26

5

32

33

31

31
TM 9-2320-364-20-5

 21-17

(5) Position water pump (22) on bracket (20).

(6) Install wire 1644 (28) and nut (30) on water

pump (22).

(7) Install wire 1435 (27) and nut (29) on water

pump (22).
TM 9-2320-364-20-5

21-18 

21-6. ARCTIC KIT WATER PUMP REPLACEMENT (CONT).

(8) Slide clamp (15) on hose (16), rotate water

pump (22) to the right and install hose on

fitting (23).

(9) Tighten clamp (15) to 40 lb-in (5 N.

m).

NOTE

Ensure matchmarks are aligned

on water pump and bracket.

(10) Reposition water pump (22) on bracket

(20).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in well

ventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(11) Apply adhesive to rubber pad (21) and

install rubber pad on clamping bracket (19).

(12) Install clamping bracket (19) on water

pump (22) and bracket (20) with two screws

(18) and locknuts (17).

(13) Install screw (25), nut (24) and bracket (26)

on bracket (20).
TM 9-2320-364-20-5

 21-19

(14) Install hose (13) on fitting (14) and tighten clamp (12) to 40 lb-in (5 N.m).

(15) Close front access cover (11) and latch by twisting handle (10).

(16) Open ball valve (9).
TM 9-2320-364-20-5

21-20 

21-6. ARCTIC KIT WATER PUMP REPLACEMENT (CONT).

(17) Install left side noise panel (8) with eight

screws (7).

(18) Open ball valve (6).
TM 9-2320-364-20-5

 21-21

(19) Install cab engine access panel (4) on cab (5)

with 22 washers (3), lockwashers (2) and

screws (1).

c. Follow-On Maintenance:

• Check coolant level, (TM 9-2320-364-10).

• Start engine, (TM 9-2320-364-10).

• Allow engine to run for three minutes.

• Shut OFF engine, (TM 9-2320-364-10).

• Check for coolant leaks, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

21-22 

Materials/Parts

Antifreeze (Item 19, Appendix C)

Gasket (Item 65, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Pan, Drain (Item 47, Appendix G)

Wrench, Torque (0-60 N.

m)

(Item 98, Appendix G)

21-7. ARCTIC KIT WATERJACKET REPLACEMENT.

Materials/Parts - Continued

Locknut (2) (Item 102, Appendix F)

Locknut (3) (Item 140, Appendix F)

Lockwasher (22) (Item 195, Appendix F)

a. Removal.

Do not remove hoses when cooling system is hot; steam and hot coolant can escape and burn

personnel.

(1) Remove 22 screws (1), lockwashers (2), washers (3) and cab engine access panel (4) from cab (5).
TM 9-2320-364-20-5

 21-23

NOTE

There are two ball valves. Both ball valves operate the same way.

(2) Shut off ball valve (6).

(3) Remove eight screws (7) and left side noise panel (8).
TM 9-2320-364-20-5

21-24 

21-7. ARCTIC KIT WATERJACKET REPLACEMENT (CONT).

(4) Shut off ball valve (9).

(5) Twist handle (10) and open front access cover (11).

(6) Position drain pan under arctic waterjacket (12).

(7) Remove plug (13) and gasket (14) from arctic waterjacket (12) and allow coolant to drain. Discard gasket.
TM 9-2320-364-20-5

 21-25

(8) Loosen clamp (15) and remove hose (16) and clamp from arctic waterjacket (12).

Sharp edges of exhaust pipe could

cause injury to personnel.

(9) Loosen clamp (17) and remove exhaust

pipe (18) and clamp from arctic

waterjacket (12).

(10) Loosen clamp (19) and remove hose (20)

and clamp from arctic waterjacket (12).

(11) Remove screw (21) from clamp (22).
TM 9-2320-364-20-5

21-26 

21-7. ARCTIC KIT WATERJACKET REPLACEMENT (CONT).

(12) Remove locknut (23), washer (24), safety

chain (25) and screw (26) from clamp (27).

Discard locknut.

Coolant may run out of water

jacket when turned. Wear eye

protection or injury to personnel

may result.

(13) Remove arctic waterjacket (12) from

clamps (22) and (27).

(14) Remove clamps (22) and (27) from two

holders (28).

(15) Remove locknut (29), screw (30) and 

holder (28) from bracket (31). Discard 

locknut.

(16) Remove locknut (36), screw (37) and

holder (28) from bracket (34). Discard

locknuts.

(17) Remove two locknuts (32), screws (33), 

and bracket (34) with holder (28) from 

frame (35). Discard locknuts.
TM 9-2320-364-20-5

 21-27

b. Installation.

(1) Install bracket holder (28) on bracket (34)

with screw (37) and locknut (36).

(2) Install bracket holder (28) with bracket (34)

on frame (35) with two screws (33) and

locknuts (32).

(3) Install bracket holder (28) on bracket (31)

with screw (30) and locknut (29).

(4) Position clamps (22) and (27) in

holders (28).

(5) Position arctic waterjacket (12) in

clamps (22) and (27).

(6) Position clamp (15) and install hose (16) on

arctic waterjacket (12).
TM 9-2320-364-20-5

21-28 

21-7. ARCTIC KIT WATERJACKET REPLACEMENT (CONT).

Sharp edges of exhaust pipe could

cause injury to personnel.

(7) Position clamps (15) and (17), hose (20) and

exhaust pipe (18) on arctic waterjacket (12).

(8) Install screw (26) in clamp (27).

(9) Install safety chain (25), washer (24) and

locknut (23) on screw (26).

(10) Install screw (21) in clamp (22).
TM 9-2320-364-20-5

 21-29

(11) Tighten clamp (15) on hose (16) to 40 lb-in

(5 N.

m).

(12) Tighten clamp (17) on exhaust tube (18).

(13) Tighten clamp (19) on hose (20).

(14) Install gasket (14) and plug (13) in arctic

waterjacket (12).

(15) Close front access cover (11) and latch by

twisting handle (10).

(16) Open ball valve (9).
TM 9-2320-364-20-5

21-30 

21-7. ARCTIC KIT WATERJACKET REPLACEMENT (CONT).

(17) Install left side noise panel (8) with eight

screws (7).

(18) Open ball valve (6).

(19) Install cab engine access panel (4) on cab

(5) with 22 washers (3), lockwashers (2)

and screws (1).

c. Follow-On Maintenance:

• Check coolant level, (TM 9-2320-364-10).

• Start engine, (TM 9-2320-364-10).

• Allow engine to run for three minutes.

• Shut OFF engine, (TM 9-2320-364-10).

• Check for coolant leaks, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 21-31

Materials/Parts

Cable Ties (Item 25, Appendix C)

Tags, Identification (Item 88, Appendix C)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

21-8. ARCTIC KIT WIRE HARNESS REPLACEMENT.

a. Removal.

(1) Remove 10 screws (1) and Electronic Control Box (ECB) right side panel (2) from cab (3).
TM 9-2320-364-20-5

21-32 

21-8. ARCTIC KIT WIRE HARNESS REPLACEMENT (CONT).

NOTE

• Connectors are removed by gently prying up on tab and pulling connectors apart.

• Tag and mark all wires and connectors prior to removal.

• Remove cable ties as required.

(2) Disconnect MC120 connector (4).

(3) Twist handle (5) and open front access cover (6).

(4) Remove nut (7) and wire 1644 (8) from water pump (9).

(5) Remove nut (10) and wire 1435 (11) from water pump (9).

b. Installation.

NOTE

Install cable ties as required.

(1) Install wire 1435 (11) and nut (10) on water pump (9).

(2) Install wire 1644 (8) and nut (7) on water pump (9).

(3) Close front access cover (6) and latch by twisting handle (5).
TM 9-2320-364-20-5

 21-33

(4) Connect MC120 connector (4).

(5) Install ECB right side panel (2) in cab (3)

with 10 screws (1).

c. Follow-On Maintenance:

• Connect batteries connected, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

21-34 

Materials/Parts

Cable Ties (Item 25, Appendix C)

Tags, Identification (Item 88, Appendix C)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

21-9. ARCTIC KIT JUMPERWIRE HARNESS REPLACEMENT.

a. Removal.

(1) Remove 15 screws (1) and left and right Electronic Control Box (ECB) covers (2) from ECB (3).
TM 9-2320-364-20-5

 21-35

NOTE

• Connectors are removed by

gently prying up on tab and

pulling connectors apart.

• Tag and mark all wires and

connectors prior to removal.

• Remove cable ties as

required.

(2) Disconnect MC101 connector (4).

(3) Loosen screw (5) and remove wire 1340 (6)

from 24V receptacle (7).

(4) Support 24V receptacle (7) and remove

nut (8) and wire 1435 (9) from 24V

receptacle (7).

b. Installation.

NOTE

Install cable ties as required.

(1) Support 24V receptacle (7) and install wire

1435 (9) and nut (8) on 24V receptacle (7).

(2) Install wire 1340 (6) on 24V receptacle (7)

and tighten screw (5).

(3) Connect MC101 connector (4).

(4) Install left and right ECB covers (2) on

ECB (3) with 15 screws (1).

c. Follow-On Maintenance:

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

21-36 

Materials/Parts

Cable Ties (Item 25, Appendix C)

Tags, Identification (Item 88, Appendix C)

Locknut (2) (Item 103, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

21-10. ARCTIC KIT SWITCH WIRE HARNESS REPLACEMENT.

a. Removal.

(1) Remove eight screws (1) and heater compartment access panel (2) from heater compartment (3).
TM 9-2320-364-20-5

 21-37

(2) Remove 15 screws (4) and left and right

Electronic Control Box (ECB) covers (5)

from ECB (6).

(3) Remove four screws (7) and tilt front heater

control panel (8) forward away from heater

compartment (3).
TM 9-2320-364-20-5

21-38 

21-10. ARCTIC KIT SWITCH WIRE HARNESS REPLACEMENT (CONT).

NOTE

• Tag and mark all wire connectors.

• Cut cable ties as required.

(4) Disconnect MC119 connector (9).

(5) Disconnect S 29 connector (10) from arctic pump switch (11).

(6) Disconnect arctic pump switch light (12) from arctic pump switch (11).

(7) Remove two locknuts (13), screws (14) and arctic pump relay sockets (15) from front heater control

panel (8). Discard locknuts.

b. Installation.

NOTE

Install cable ties as required.

(1) Install arctic pump relay sockets (15), two screws (14) and locknuts (13) on front heater control panel (8).

(2) Connect arctic pump switch light (12) on arctic pump switch (11).

(3) Connect S 29 connector (10) on arctic pump switch (11).

(4) Connect MC119 connector (9).
TM 9-2320-364-20-5

 21-39

(5) Install front heater control panel (8) on

heater compartment (3) with four screws (7).

(6) Install left and right ECB covers (5) on

ECB (6) with 15 screws (4).

(7) Install heater compartment access panel (2)

on heater compartment (3) with eight

screws (1).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

21-40 

Materials/Parts

Compound, Corrosion Preventive

(Item 35, Appendix C)

Tags, Identification (Item 88, Appendix C)

This task covers:

a. Disconnection b. Connection c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

21-11. ARCTIC KIT BATTERY DISCONNECTION/CONNECTION.

a. Disconnection.

(1) Remove two flip rings (1) from arctic battery

box (2).

(2) Slide battery box (2) out.

(3) Disconnect two latches (3) from battery box

cover (4).

(4) Remove arctic battery box cover (4) from

battery box (2).
TM 9-2320-364-20-5

 21-41

• Upon removal of all wires and cables, ensure no contact is made with battery terminals or

other wires and cables. Strap wires and cables away from battery terminals and other wires

and cables as required to prevent damage to parts, personal injury, or death.

• Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and rubber

gloves, and do not smoke when preforming maintenance on batteries. Injury will result if

acid contacts skin or eyes. Wear rubber apron to prevent clothing being damaged.

• Remove all jewelry such as rings, dog tags, bracelets, etc. If jewelry or tools contact

positive electrical circuits, a direct short may result. Damage to equipment, injury or death

to personnel may occur.

NOTE

Tag and mark wires prior to removal.

(5) Loosen two nuts (5) and remove two

terminals (6) from negative battery posts (7)

on arctic batteries (8).

(6) Loosen two nuts (9) and remove two

terminals (10) from positive battery

posts (11) on arctic batteries (8).

b. Connection.

(1) Install two terminals (10) on positive battery

posts (11) and tighten two nuts (9) to 84 to

96 lb-in (9 to 11 N.

m).

(2) Install two terminals (6) on negative battery

posts (7) and tighten two nuts (5) to 84 to 96

lb-in (9 to 11 N.

m).

Corrosion inhibitor contains

alkali. Do not get in eyes; wear

goggles/safety glasses when

using. Avoid contact with skin.

In case of contact, immediately

wash area with soap and water. If

eyes are contacted, flush eyes

with large amounts of water for at

least 15 minutes and get

immediate medical attention.

(3) Apply corrosion preventive compound to

positive posts (11), negative posts (7) and

terminals (10) and (6).
TM 9-2320-364-20-5

21-42 

21-11. ARCTIC KIT BATTERY DISCONNECTION/CONNECTION (CONT).

(4) Install arctic battery cover (4) on battery

box (2).

(5) Connect two latches (3) to battery box

cover (4).

(6) Push in battery box (2) into stored position.

(7) Install two flip rings (1) on battery box (2).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 21-43

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Hydraulic reservoir drained, (Para 20-11)

Interface hydraulic hoses and tubes 

removed, (Para 20-3)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

21-12. INTERFACE QUICK DISCONNECT ASSEMBLY REPLACEMENT.

Materials/Parts

Lockwasher (4) (Item 172, Appendix F)

a. Removal.

(1) Remove four nuts (1), lockwashers (2),

washers (3), screws (4) and quick disconnect

assembly (5) from mounting bracket (6).

Discard lockwashers.

2

3

4

5

6

1
TM 9-2320-364-20-5

21-44 

21-12. INTERFACE QUICK DISCONNECT ASSEMBLY REPLACEMENT (CONT).

b. Installation.

(1) Position four screws (4) in quick disconnect

assembly (5).

(2) Install quick disconnect assembly (5) on

mounting bracket (6) with four screws (4),

washers (3), lockwashers (2) and nuts (1).

c. Follow-On Maintenance:

• Install interface hydraulic hoses and tubing, (Para 20-3).

• Fill hydraulic reservoir, (Para 20-11).

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

2 3

4

5

6

1
TM 9-2320-364-20-5

 21-45

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Quick disconnect removed, (Para 21-12)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

21-13. INTERFACE MOUNTING BRACKET REPLACEMENT.

Materials/Parts

Sealing Compound (Item 72, Appendix C)

Locknut (5) (Item 104, Appendix F)

Locknut (4) (Item 106, Appendix F)

Locknut (4) (Item 107, Appendix F)

Locknut (4) (Item 140, Appendix F)

Lockwasher (Item 158, Appendix F)

a. Removal.

(1) Remove cap (1) from MC130 connector (2).

(2) Remove cap (3) from MC138 connector (4).

4

2

3

1
TM 9-2320-364-20-5

21-46 

21-13. INTERFACE MOUNTING BRACKET REPLACEMENT. (CONT).

(3) Remove locknut (5), screw (6), cap with

chain (1) and cap with chain (3) from

interface mounting bracket (7). Discard

locknut.

(4) Remove four locknuts (8), screws (9) and

MC130 connector (2) from interface

mounting bracket (7). Discard locknuts.

(5) Remove four locknuts (10), screws (11) and

MC138 connector (4) from interface

mounting bracket (7). Discard locknuts.

(6) Remove four locknuts (12), screws (13), two

cover plates (14), four clamp halves (15),

tube 2810 (16) and tube 2724 (17) from

interface mounting bracket (7). Discard

locknuts.

(7) Remove cover (18) from air quick disconnect (19).

(8) Remove air line 2133 (20) from fitting (21).

(9) Remove fitting (21) from fitting (22).

(10) Remove quick disconnect (19) from fitting (22).

(11) Remove jam nut (23), lockwasher (24) and

fitting (22) from interface mounting bracket

(7). Discard lockwasher.

21 20

22

7

19 24

23

18

10

8

3

1

9

4

2

7

16

13

12

13

15

17

12

6

7

14

14

5

15

11
TM 9-2320-364-20-5

 21-47

(12) Remove four locknuts (25), screws (26) and

interface mounting bracket (7) from step

(27). Discard locknuts.

b. Installation.

NOTE

Use existing holes in step to

mount interface mounting

bracket. Rear inside screw should

be located in first hole from the

rear and first row from inside.

(1) Install interface mounting bracket (7) to step

(27) with four screws (26) and locknuts (25).

(2) Install fitting (22) in interface mounting

bracket (7) with lockwasher (24) and jam nut

(23).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(3) Apply sealing compound on threads of

fitting (22).

(4) Install quick disconnect (19) on fitting (22).

(5) Apply sealing compound on threads of

fitting (21).

(6) Install fitting (21) in fitting (22).

(7) Install air line 2133 (20) on fitting (21).

(8) Install cover (18) on air quick disconnect

(19).

25

27

26

7

21 20

22

7

19 24

23

18
TM 9-2320-364-20-5

21-48 

21-13. INTERFACE MOUNTING BRACKET REPLACEMENT. (CONT).

(9) Install four clamp halves (15), two cover

plates (14), four screws (13), locknuts (12),

tube 2810 (16) and tube 2724 (17) on

interface mounting bracket (7).

(10) Position MC138 connector (4) through slots

in interface mounting bracket (7) and install

with four screws (11) and locknuts (10).

(11) Install MC130 connector (2) to interface

mounting bracket (7) with four screws (9)

and locknuts (8).

(12) Install cap with chain (1) and cap with chain

(3) with screw (6) and locknut (5) on

interface mounting bracket (7).

(13) Install cap (1) on MC130 connector (2).

(14) Install cap (3) on MC138 connector (4).

c. Follow-On Maintenance:

• Install quick disconnect, (Para 21-12).

• Start engine and check for air leaks.

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

10

8

3

1

9

4

2

7

16

13

12

13

15

17

12

6

7

14

14

5

15

11
TM 9-2320-364-20-5

 21-49

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

21-14. INTERFACE WIRING HARNESS REPLACEMENT.

Materials/Parts

Cable Ties (Item 26, Appendix C)

Tags, Identification (Item 88, Appendix C)

Locknut (8) (Item 104, Appendix F)

Locknut (8) (Item 107, Appendix F)

Locknut (Item 140, Appendix F)

Materials/Parts (cont)

Lockwasher (Item 174, Appendix F)

Lockwasher (26) (Item 195, Appendix F)

Lockwasher (Item 196, Appendix F)

Lockwasher (Item 198, Appendix F)

a. Removal.

NOTE

• Tag and mark all wires and

connectors prior to removal.

• Remove cable ties as

required.

(1) Remove cap (1) from MC130 connector (2).

(2) Remove four locknuts (3), screws (4) and

MC130 connector (2) from bracket (5).

Discard locknuts.

(3) Remove cap (6) from MC138 connector (7).

(4) Remove four locknuts (8), screws (9) and

MC138 connector (7) from bracket (5).

Discard locknuts.

4

2

8

9

3

5

1

6

7
TM 9-2320-364-20-5

21-50 

21-14. INTERFACE WIRING HARNESS REPLACEMENT (CONT).

(5) Remove nut (10) from fitting (11).

(6) Remove fitting (11) from female quick

disconnect (12).

NOTE

Tag and mark wires prior to

removal.

(7) Remove wires 1435 (13), 1435A (14) and

1435B (15) from three terminals (16), (17)

and (18).

11 10

12

15

14

13

18

17

16
TM 9-2320-364-20-5

 21-51

(8) Disconnect power cable MC29 connector (19) from connector (20).

(9) Disconnect MC135 connector (21) and MC136 connector (22) from powerbox (23).

20 19

21

22

23
TM 9-2320-364-20-5

21-52 

21-14. INTERFACE WIRING HARNESS REPLACEMENT (CONT).

(10) Loosen screw (24) and remove MC134 connector (25) from valve (26).

(11) Loosen screw (27) and remove MC133 connector (28) from valve (29).

25 24

26

29

28 27
TM 9-2320-364-20-5

 21-53

(12) Loosen screw (30) and remove MC132 connector (31) from connector (32).

• Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and rubber

gloves, and do not smoke when performing maintenance on batteries. Injury will result if

acid contacts skin or eyes. Wear rubber apron to prevent clothing being damaged.

• Remove all jewelry such as rings, dog tags, bracelets, etc. If jewelry or tools contact

positive electrical circuits, a direct short may result. Damage to equipment, injury or death

to personnel may occur.

(13) Remove nut (33), lockwasher (34), washer (35) and wire 1435 (36) from negative terminal (37). 

Discard lockwasher.

30

31

32

33

34

35

36

37
TM 9-2320-364-20-5

21-54 

21-14. INTERFACE WIRING HARNESS REPLACEMENT (CONT).

(14) Remove four screws (38), lockwashers (39),

washers (40) and cover (41) from splash

guard (42). Discard lockwashers.

(15) Remove nut (43), lockwasher (44) and wire

1785 (45) from 12V BAT terminal (46).

Discard lockwasher.

(16) Remove nut (47), lockwasher (48) and wire

1784 (49) from 24V BAT terminal (50).

Discard lockwasher.

38 39

40

42

41

43

44

48

47

46

50

45

49
TM 9-2320-364-20-5

 21-55

(17) Remove 22 screws (51), lockwashers (52)

and washers (53) from cab engine access

panel (54). Discard lockwashers.

(18) Position cab engine access panel (54) to

access MC129 connector (55).

(19) Remove cap (56) from MC129 connector

(55).

(20) Remove four locknuts (57), screws (58) and

MC129 connector (55) from cab engine

access panel (54). Discard locknuts.

(21) Remove cap (59) from MC137 connector

(60).

(22) Remove four locknuts (61), screws (62) and

MC137 connector (60) from cab engine

access panel (54). Discard locknuts.

DOOR

SHOWN

REMOVED

FOR CLARITY

51

53

52

54

55

56

58

57

61

62

60

59 55

60

55
TM 9-2320-364-20-5

21-56 

21-14. INTERFACE WIRING HARNESS REPLACEMENT (CONT).

NOTE

Note location of cushion clips prior to removal.

(23) Remove locknut (63) and cushion clip (64) from U-bolt (65). Discard locknut.

(24) Remove wiring harness (66) from truck.

b. Installation.

NOTE

Install cable ties as required.

(1) Position wire harness (66) in truck.

64

63

66

65
TM 9-2320-364-20-5

 21-57

(2) Install MC137 connector (60) to cab engine

access panel (54) with four screws (62) and

locknuts (61).

(3) Install cap (59) on MC137 connector (60).

(4) Install MC129 connector (55) to cab engine

access panel (54) with four screws (58) and

locknuts (57).

(5) Install cap (56) on MC129 connector (55).

(6) Install cab engine access panel (54) with 22

screws (51), lockwashers (52) and washers

(53).

56

58

57

61

62

60

59 55

60

55

51

53

52

54
TM 9-2320-364-20-5

21-58 

21-14. INTERFACE WIRING HARNESS REPLACEMENT (CONT).

(7) Install wire 1784 (49), lockwasher (48) and

nut (47) on 24V BAT terminal (50).

(8) Install wire 1785 (45), lockwasher (44) and

nut (43) on 12V BAT terminal (46).

(9) Install cover (41) with four screws (38),

washers (40) and lockwashers (39) on splash

guard (42).

43

44

48

47

46

50

45

49

39 38

40

42

41
TM 9-2320-364-20-5

 21-59

• Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and rubber

gloves, and do not smoke when performing maintenance on batteries. Injury will result if

acid contacts skin or eyes. Wear rubber apron to prevent clothing being damaged.

• Remove all jewelry such as rings, dog tags, bracelets, etc. If jewelry or tools contact

positive electrical circuits, a direct short may result. Damage to equipment, injury or death

to personnel may occur.

(10) Install wire 1435 (36), washer (35), lockwasher (34) and nut (33) to negative terminal (37).

(11) Install MC132 connector (31) to M10

connector (32) and tighten screw (30).

33

34

35

36

37

30

31

32
TM 9-2320-364-20-5

21-60 

21-14. INTERFACE WIRING HARNESS REPLACEMENT (CONT).

(12) Install MC133 connector (28) to valve (29)

and tighten screw (27).

(13) Install MC134 connector (25) to valve (26)

and tighten screw (24).

25

24

26

29

28 27
TM 9-2320-364-20-5

 21-61

(14) Install MC135 connector (21) and MC136 connector (22) to powerbox (23).

(15) Connect power cable MC29 connector (19) to connector (20).

21

22

23

20

19
TM 9-2320-364-20-5

21-62 

21-14. INTERFACE WIRING HARNESS REPLACEMENT (CONT).

(16) Position wire 1435 (13), 1435A (14) and

1435B (15) through nut (10) and fitting

(11).

(17) Install wire 1435 (13) to terminal (16).

(18) Install wire 1435A (14) to terminal (17).

(19) Install wire 1435B (15) to terminal (18).

(20) Install fitting (11) on female quick

disconnect (12).

(21) Install nut (10) on fitting (11).

11 10

12

15

14

13

18

17

16
TM 9-2320-364-20-5

 21-63

(22) Install MC138 connector (7) on bracket (5)

with four screws (9) and locknuts (8).

(23) Install cap (6) on MC138 connector (7).

(24) Install MC130 connector (2) on bracket (5)

with four screws (4) and locknuts (3).

(25) Install cap (1) on MC130 connector (2).

(26) Position wiring harness (66) in cushion clip (64).

(27) Install cushion clip (64) and locknut (63) on U–bolt (65).

c. Follow-on Maintenance:

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

4

2

8

9

3

5

1

6

7

64 65 63

66
TM 9-2320-364-20-5

21-64 

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Materials/Parts

Solvent, Drycleaning (Item 87, Appendix C)

Tags, Identification (Item 88, Appendix C)

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Interface wiring harness disconnected, 

(Para 21-14)

Powerbox wiring removed, (Para 21-16)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Drill, Electric, Portable 1/4” 

(Item 17, Appendix G)

Drill Set, Twist (Item 19, Appendix G)

Gloves, Chemical Oil Protective 

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

21-15. INTERFACE POWERBOX ASSEMBLY REPAIR.

Materials/Parts (cont)

Locknut (4) (Item 104, Appendix F)

Locknut (4) (Item 106, Appendix F)

Locknut (4) (Item 107, Appendix F)

Lockwasher (3) (Item 205, Appendix F)

a. Removal.

(1) Remove four screws (1), locknuts (2) and powerbox (3) from left front fender (4). Discard locknuts.

1

3

2

4
TM 9-2320-364-20-5

 21-65

b. Disassembly.

NOTE

Note location and position of

connectors, terminal strip, relays

and rectifier prior to removal.

(1) Remove four locknuts (1), screws (2) and 8

pin connector (3) from powerbox (4).

Discard locknuts.

(2) Remove four locknuts (5), screws (6), 4 pin

connector (7) and LED (8) from powerbox

(4). Discard locknuts.

(3) Remove two screws (9) and terminal strip

(10) from powerbox (4).

(4) Remove four screws (11) and two relays (12)

from powerbox (4).

(5) Remove screw (13) and rectifier (14) from

powerbox (4).

4

2

6

3

7

5

1

8

11

12

9

4

11

12

10

13

14
TM 9-2320-364-20-5

21-66 

21-15. INTERFACE POWERBOX ASSEMBLY REPAIR (CONT).

NOTE

Tag and mark circuit breakers

prior to removal.

(6) Remove nut (15), circuit breaker (16) and

lockwasher (17) from powerbox (4).

Discard lockwasher.

(7) Repeat Step (6) for remaining two circuit

breakers (16).

NOTE

Before removal of insulator

mounting plate, all components

must be removed.

(8) Remove four screws with captive

lockwashers (18) and insulator mounting

plate (19) from powerbox (4).

16

17

15 16 16

18

19

4

4
TM 9-2320-364-20-5

 21-67

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

(1) Wash metal parts in drycleaning solvent.

(2) Inspect metal parts for cracks, dents, and broken welds. Replace damaged parts.

(3) Inspect relays and terminal strip for cracks, broken terminals and stripped threads. Replace damaged

parts.

(4) Check wires for loose or broken connections, or mission insulation. Replace damaged parts.
TM 9-2320-364-20-5

21-68 

21-15. INTERFACE POWERBOX ASSEMBLY REPAIR (CONT).

d. Assembly.

(1) Install insulator mounting plate (19) with

four screws with captive lockwashers (18) in

powerbox (4).

NOTE

• Install circuit breakers as

noted prior to removal.

• 2 AMP circuit breaker is at

bottom left. 25 AMP

breakers are at bottom center

and right.

(2) Install three circuit breakers (16) in

powerbox (4) with three lockwashers (17)

and nuts (15).

18

19

4

16

17

15 16 16

4
TM 9-2320-364-20-5

 21-69

NOTE

Install rectifier, relays, terminal

strip and connectors in position

and location as noted prior to

removal.

(3) Install rectifier (14) with screw (13) in

powerbox (4).

(4) Install two relays (12) with four screws (11)

in powerbox (4).

(5) Install terminal strip (10) with two screws

(9) in powerbox (4).

(6) Install 4 pin connector (7) and LED (8) in

powerbox (4) with four screws (6) and

locknuts (5).

(7) Install 8 pin connector (3) in powerbox (4)

with four screws (2) and locknuts (1).

4

2

6

3

7

5

1

8

11

12

9

4

11

12

10

13

14
TM 9-2320-364-20-5

21-70 

21-15. INTERFACE POWERBOX ASSEMBLY REPAIR (CONT).

e. Installation.

(1) Install powerbox (3) on left front fender (4) with four screws (1) and locknuts (2).

f. Follow-On Maintenance:

• Install powerbox wiring, (Para 21-16).

• Connect interface wiring harness, (Para 21-14).

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

3

1

4

2
TM 9-2320-364-20-5

 21-71

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

21-16. INTERFACE POWERBOX WIRING REPLACEMENT.

Materials/Parts

Tags, Identification (Item 88, Appendix C)

a. Removal.

NOTE

This procedure shows removal of

interface wiring for interface

power box. Only remove wiring

that is required to complete task.

(1) Loosen four screws (1) and remove cover (2)

from powerbox (3).

1

3

2
TM 9-2320-364-20-5

21-72 

21-16. INTERFACE POWERBOX WIRING REPLACEMENT (CONT).

NOTE

• Disconnect only wires required to complete task. Refer to the electrical schematic drawing

3123995 and Table 21-1 Powerbox Wiring for specific powerbox wiring replacement.

• Tag and mark wires prior to removal. 

(2) Follow Table 21-1 to disconnect wires.

Table 21-1. Powerbox Wiring

Cable No. Color From To

1785 BLK 4 Pin Connector-A (MC136) (4) CB27/25AMP - Front (5)

1785 BLK 4 Pin Connector-B (MC136) (4) CB27/25AMP - Back (5)

1784 BLK 4 Pin Connector-D (MC136) (4) CB28/25AMP - Front (6)

1784 BLK 4 Pin Connector-C (MC136) (4) CB28/25AMP - Back (6)

1784 BLK CB28/25AMP - Front (6) CB29/2AMP - Front (7)

1789 BLK CB29/2AMP - Back (7) Relay R36 / Terminal 30 (8)

1435 BLK Rectifier/AC (9) Relay R36 / Terminal 85 (8)

1435A BLK Rectifier/+ (9) MC 135 / 8 Pin Connector - H (10)

AC

4

6 5 7

8

10

AC

86 85 30 87

30 87

86 85

9
TM 9-2320-364-20-5

 21-73

Table 21-1. Powerbox Wiring – CONT.

Cable No. Color From To

1734 BLK Rectifier/AC (9) Terminal 13 (11)

1435 BLK Relay R36/Terminal 85 (8) Terminal 7 (11)

1731 BLK Relay R36/Terminal 86 (8) Terminal 8 (11)

1792 BLK Relay R36/Terminal 87 (8) Terminal 10 (11)

1734 BLK Relay R35/Terminal 30 (12) Terminal 1 (11)

1790 BLK Relay R35/Terminal 87 (12) Terminal 2 (11)

1435 BLK Relay R35/Terminal 85 (12) Terminal 4 (11)

1734 BLK Relay R35/Terminal 86 (12) Terminal 3 (11)

1734 BLK Terminal 11 (11) MC135 / 8 Pin Connector - B (10)

1790 BLK Terminal 12 (11) MC135 / 8 Pin Connector - D (10)

1435 BLK Terminal 14 (11) MC135 / 8 Pin Connector - C (10)

1435 BLK Terminal 14 (11) MC135 / 8 Pin Connector - E (10)

1731 BLK Terminal 18 (11) MC135 / 8 Pin Connector - A (10)

1435B BLK Terminal 19 (11) MC135 / 8 Pin Connector - G (10)

1792 BLK Terminal 20 (11) MC135 / 8 Pin Connector - F (10)

AC

AC

8

12

9

TOP

11

5

6

7

8

9

10

12

13

14

15

16

17

18

19

20

BOTTOM

1

2

3

4

11

10

30 87

86 85

30 87

86 85
TM 9-2320-364-20-5

21-74 

21-16. INTERFACE POWERBOX WIRING REPLACEMENT (CONT).

Table 21-1. Powerbox Wiring – CONT.

Cable No. Color From To

1734 BLK Terminal 1 (11) Terminal 3 (11)

LED#1 RED Green LED (13) Terminal 20 (11)

LED#1 WHITE Green LED (13) Terminal 19 (11)

LED#2 RED Yellow LED (14) Terminal 4 (11)

LED#2 WHITE Yellow LED (14) Terminal 12 (11)

LED#3 RED Green LED (15) Terminal 18 (11)

LED#3 WHITE Green LED (15) Terminal 17 (11)

AC

AC

TOP

11

5

6

7

8

9

10

12

13

14

15

16

17

18

19

20

BOTTOM

1

2

3

4

11

15

13

14

30 87

86 85

30 87

86 85
TM 9-2320-364-20-5

 21-75

b. Installation.

NOTE

Connect only wires required to complete task. Refer to the electrical schematic drawing

3123995 and Table 21-1 Powerbox Wiring for specific powerbox wiring replacement.

(1) Follow Table 21-1 to connect wires.

(2) Position cover (2) on power box (3).

(3) Tighten four screws (1) on cover (2).

c. Follow-On Maintenance:

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

1

3

2
TM 9-2320-364-20-5

21-76 

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and plug set (Item 8, Appendix G)

Pan, Drain (Item 47, Appendix G)

21-17. INTERFACE AUXILIARY HYDRAULIC VALVE REPLACEMENT.

Materials/Parts

Oil, Hydraulic (Item 50, Appendix C)

Tags, Identification (Item 88, Appendix C)

Lockwasher (Item 168, Appendix F)

Preformed Packing (Item 233, Appendix F)

Preformed Packing (Item 237, Appendix F)

Preformed Packing (2) (Item 252, Appendix F)

Preformed Packing (Item 250, Appendix F)

Preformed Packing (Item 235, Appendix F)
TM 9-2320-364-20-5

 21-77

a. Removal.

The hydraulic system operates at

high pressures. Never disconnect

any hydraulic line or fitting

without first dropping pressure to

zero. Failure to comply may

result in serious injury or death to

personnel.

NOTE

• Tag and mark hoses prior to

removal.

• Cap and plug hoses after

removal.

• Position drain pan under

valve.

(1) Loosen screw (1) and disconnect MC134

connector (2) from auxiliary hydraulic valve

(3).

(2) Remove hose 2810 (4), preformed packing

(5), fitting (6) and preformed packing (7).

Discard preformed packings.

(3) Remove hose 2902 (8), preformed packing

(9), elbow (10) and preformed packing (11).

Discard preformed packings.

(4) Remove hose 2774 (12), preformed packing

(13), elbow (14) and preformed packing

(15). Discard preformed packings.

(5) Remove four screws (16), lockwashers (17),

washers (18) and auxiliary hydraulic valve

(3) from fender (19). Discard lockwashers.

18

16

17

1

2

3

14

13

12

10

9

8

4

5 6 7

15

11

19
TM 9-2320-364-20-5

21-78 

21-17. INTERFACE AUXILIARY HYDRAULIC VALVE REPLACEMENT (CONT).

b. Installation.

(1) Install auxiliary hydraulic valve (3) on

fender (19) with four screws (16),

lockwashers (17) and washers (18).

(2) Apply hydraulic oil to preformed packings

(5), (7), (9), (11), (13) and (15).

(3) Install preformed packing (15), elbow 

(14), preformed packing (13) and hose 

2774 (12) on auxiliary hydraulic valve (3).

(4) Install preformed packing (11), elbow (10),

preformed packing (9) and hose 2902 (8) on

auxiliary hydraulic valve (3).

(5) Install preformed packing (7), fitting (6),

preformed packing (5) and hose 2810 (4) 

on auxiliary hydraulic valve (3).

(6) Connect MC134 connector (2) to auxiliary

hydraulic valve (3) and tighten screw (1).

c. Follow-on Maintenance:

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

18

16

17

1

2

3

14

13

12

10

9

8

4

5 6 7

15

11

19
TM 9-2320-364-20-5

 21-79

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheel chocked, (TM 9-2390-364-10)

Batteries disconnected, (Para 7-87)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Cap and Plug Set (Item 8, Appendix G)

Pan, Drain, 4 Gallon (Item 47, Appendix G)

Socket Set, 3/8 in. Drive (Item 62, Appendix G)

Wrench, Torque 3/8 in. Drive (0-60 N.

m)

(Item 98, Appendix G)

21-18. INTERFACE MANUAL OVERRIDE SOLENOID VALVE REPLACEMENT.

Materials/Parts

Gasket (Item 59, Appendix F)

Kit, Packing (Item 87, Appendix F)

a. Removal.

(1) Loosen screw (1) and remove connector MC134 (2) and gasket (3) from coil (4). Discard gasket.

3

4

1

2
TM 9-2320-364-20-5

21-80 

21-18. INTERFACE MANUAL OVERRIDE SOLENOID VALVE REPLACEMENT (CONT).

NOTE

Pull button out and turn to access

screw.

(2) Loosen screw (5) and remove button (6)

from valve (7).

(3) Remove nut (8) and coil (4) from valve (7).

(4) Remove valve (7) from auxiliary supply

valve (9).

(5) Remove three back-up rings (10) and four

preformed packings (11) from valve (7).

Discard back-up rings and preformed

packings.

b. Installation.

(1) Install four preformed packings (11) and

three back-up rings (10) on valve (7).

7

9

10 10 10

11 11 11 11 7

8

6

4

5
TM 9-2320-364-20-5

 21-81

(2) Install valve (7) into auxiliary supply valve

(9).

(3) Install coil (4) on valve (7) with nut (8).

Tighten nut to 48-72 lb-in (5-8 N.

m).

(4) Install button (6) on valve (7) with screw (5).

(5) Install gasket (3) and connector MC134 (2)

on coil (4) with screw (1).

c. Follow-on Maintenance:

• Fill main hydraulic reservoir, (Para 20-11).

• Connect batteries, (Para 7-87).

• Start engine and allow to idle for five minutes, (TM 9-2320-364-10).

• Shut off engine and check for hydraulic leaks, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

7

9

8

6

4

5

3

4

1

2
TM 9-2320-364-20-5

21-82

21-19. CONTAINER HANDLING UNIT (CHU) JUMPERWIRE HARNESS 

REPLACEMENT.

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Deck weldment removed (left side only),

(Para 21-40)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Materials/Parts

Cable Ties (Item 27, Appendix C)

Tags, Identification (Item 88, Appendix C)

a. Removal.

NOTE

• Tag and mark all wires and

connectors prior to removal.

• Note routing of CHU

jumperwire harness prior to

removal.

• Remove cable ties as

required.

(1) Disconnect MC85 connector (1) from LHS

main junction box (2).

2

1
TM 9-2320-364-20-5

 21-83

(2) Disconnect MC82B connector (3) from

CHU control box (4).

(3) Remove CHU jumper harness (5) from

truck.

b. Installation.

NOTE

• Install cable ties as required.

• Position CHU jumperwire

harness as noted during

removal.

(1) Position CHU jumper harness (5) in truck.

(2) Connect MC82B connector (3) to CHU

control box (4).

(3) Connect MC85 connector (1) to LHS main

junction box (2).

c. Follow-on Maintenance:

• Install deck weldment (left side only), (Para 21-40).

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

3

4

5

2

1
TM 9-2320-364-20-5

21-84

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Deck weldment removed (left side only),

(Para 21-40)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

21-20. CONTAINER HANDLING UNIT (CHU) WIRE HARNESS REPLACEMENT.

Materials/Parts

Cable Ties (Item 27, Appendix C)

Tags, Identification (Item 88, Appendix C)

a. Removal.

NOTE

• Tag and mark all wires and connectors prior to removal.

• Remove cable ties as required.

(1) Disconnect MC185 connector (1) from CHU control box (2).

1

2
TM 9-2320-364-20-5

 21-85

(2) Disconnect MC188 connector (3) from hook up arm proximity switch (4).

(3) Disconnect MC189 connector (5) from mode switch (6).

(4) Disconnect two MC190 connectors (7) from right and left rear lock limit switch (8).

(5) Remove CHU wire harness (9) from truck.

GROOVE

7

2 4

6

9

3

4

5

6

8
TM 9-2320-364-20-5

21-86

21-20. CONTAINER HANDLING UNIT (CHU) WIRE HARNESS REPLACEMENT (CONT).

b. Installation.

NOTE

Install cable ties as required.

(1) Position CHU wire harness (9) with MC189

connector (5) and two MC190 connectors (7)

along inside of frame (10) and in groove of

left hard lift deck bracket (11).

(2) Position CHU wire harness (9) with MC188

connector (3) along inside of frame (12) with

existing wires.

(3) Position CHU wire harness with MC185

connector (1) along inside of frame (13) with

existing wires.

(4) Connect two MC190 connectors (7) to right

and left rear lock limit switch (8).

(5) Connect MC189 connector (5) to mode

switch (6).

(6) Connect MC188 connector (3) to hook up

arm proximity switch (4).

3

4

6

5

GROOVE

7

11

1 9 13 3 12 5

8

7 11

10
TM 9-2320-364-20-5

 21-87

(7) Connect MC185 connector (1) to CHU

control box (2).

c. Follow-on Maintenance:

• Install deck weldment (left side only), (Para 21-40).

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

1

2
TM 9-2320-364-20-5

21-88

21-21. CONTAINER HANDLING UNIT (CHU) CONTROL BOX ASSEMBLY 

REPLACEMENT.

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Deck weldment removed (left side only),

(Para 21-40)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Materials/Parts

Locknut (4) (Item 103, Appendix F)

a. Removal.

(1) Disconnect MC185 connector (1), MC82B

connector (2) and MC82A connector (3)

from CHU control box assembly (4).

1

4

3

2
TM 9-2320-364-20-5

 21-89

(2) Loosen four screws (5) and remove cover (6)

from CHU control box assembly (4).

(3) Remove four screws (7), locknuts (8), and

CHU control box assembly (4) from front

support crossmember (9). Discard locknuts.

b. Installation.

(1) Install CHU control box assembly (4), four

screws (7) and locknuts (8) on front support

crossmember (9).

4

6

5

4

7

9

8
TM 9-2320-364-20-5

21-90

21-21. CONTAINER HANDLING UNIT (CHU) CONTROL BOX ASSEMBLY 

REPLACEMENT (CONT).

(2) Position cover (6) on CHU control box

assembly (4) and tighten four screws (5).

(3) Connect MC185 connector (1), MC82B

connector (2) and MC82A connector (3) on

CHU control box assembly (4).

c. Follow-on Maintenance:

• Install deck wekdment (left side only), (Para 21-40).

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

4

6

5

1

4

3

2
TM 9-2320-364-20-5

 21-91

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Disconnnect batteries, (Para 7-87)

Wheels chocked, (TM 9-2320-364-10)

CHU control box assembly removed,

(Para 21-21)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

21-22. CONTAINER HANDLING UNIT (CHU) CONTROL BOX WIRING REPLACEMENT.

Materials/Parts

Tags, Identification (Item 88, Appendix C)

a. Removal.

NOTE

This procedure shows removal of CHU wiring for CHU control box. Only remove wiring

required to complete task.

(1) Remove three nuts (1) from connectors MC82A (2), MC82B (3) and MC185 (4) on control box (5).

NOTE

• Disconnect only wires required to complete task. Refer to Table 21-2 CHU Control Box

Wiring for specific control box wiring replacement.

• Tag and mark wires prior to removal. R52 R51 R50

8

7 6

5

4 3

2

1 1

1
TM 9-2320-364-20-5

21-92

21-22. CONTAINER HANDLING UNIT (CHU) CONTROL BOX WIRING 

REPLACEMENT (CONT).

Table 21-2. CHU Control Box Wiring

Cable No. Color From To

1435 BLK 10 Pin Connector A (MC185) (4) 10 Pin Connector E (MC185) (4)

17 Pin Connector L (MC82A) (2)

17 Pin Connector L (MC82B) (3)

1474 BLK 10 Pin Connector B (MC185) (4) Relay R50/Terminal 86 (6)

1466b BLK 10 Pin Connector C (MC185) (4) Relay R50/Terminal 87 (6)

1495 BLK 10 Pin Connector D (MC185) (4) 10 Pin Connector F (MC185) (4)

Relay R50/Terminal 85 (6)

1435 BLK 10 Pin Connector E (MC185) (4) 10 Pin Connector A (MC185) (4)

17 Pin Connector L (MC82A) (2)

17 Pin Connector L (MC82B) (3)

1495 BLK 10 Pin Connector F (MC185) (4) 10 Pin Connector D (MC185) (4)

Relay R50/Terminal 85 (6)

1496 BLK 10 Pin Connector G (MC185) (4) Relay R51/Terminal 85 (7)

1465 BLK 17 Pin Connector A (MC82A) (2) Relay R52/Terminal 86 (8)

17 Pin Connector A (MC82B) (3)

1467 BLK 17 Pin Connector B (MC82A) (2) 17 Pin Connector B (MC82B) (3)

1468 BLK 17 Pin Connector C (MC82A) (2) 17 Pin Connector C (MC82B) (3)

1464 BLK 17 Pin Connector D (MC82A) (2) Relay R51/Terminal 30 (7)

1466 BLK 17 Pin Connector E (MC82A) (2) Relay R50/Terminal 30 (6)

1472 BLK 17 Pin Connector F (MC82A) (2) 17 Pin Connector F (MC82B) (3)

Relay R50/Terminal 86 (6)

1469 BLK 17 Pin Connector G (MC82A) (2) 17 Pin Connector G (MC82B) (3)

1463 BLK 17 Pin Connector H (MC82A) (2) 17 Pin Connector H (MC82B) (3)

1462 BLK 17 Pin Connector J (MC82A) (2) 17 Pin Connector J (MC82B) (3)

1435 BLK 17 Pin Connector K (MC82A) (2) Relay R52/Terminal 85 (8)

17 Pin Connector K (MC82B) (3)

1435 BLK 17 Pin Connector L (MC82A) (2) 10 Pin Connector A & E (MC185) (4)

17 Pin Connector L (MC82B) (3)

1471 BLK 17 Pin Connector M (MC82A) (2) 17 Pin Connector M (MC82B) (3)

1460 BLK 17 Pin Connector N (MC82A) (2) 17 Pin Connector N (MC82B) (3)

1459 BLK 17 Pin Connector P (MC82A) (2) 17 Pin Connector P (MC82B) (3)

1435 BLK 17 Pin Connector R (MC82A) (2) 17 Pin Connector R (MC82B) (3)

1435 BLK 17 Pin Connector S (MC82A) (2) 17 Pin Connector S (MC82B) (3)

1465 17 Pin Connector A (MC82B) (3) 17 Pin Connector A (MC82A) (2)

Relay R52/Terminal 86 (8)

1467 17 Pin Connector B (MC82B) (3) 17 Pin Connector B (MC82A) (2)

1468 17 Pin Connector C (MC82B) (3) 17 Pin Connector C (MC82A) (2)
TM 9-2320-364-20-5

 21-93

Cable No. Color From To

1464 17 Pin Connector D (MC82B) (3) Relay R51/Terminal 87A (7)

1466 BLK 17 Pin Connector E (MC82B) (3) Relay R50/Terminal 87A (6)

1472 BLK 17 Pin Connector F (MC82B) (3) 17 Pin Connector F (MC82A) (2)

Relay R50/Terminal 86 (6)

1469 BLK 17 Pin Connector G (MC82B) (3) 17 Pin Connector G (MC82A) (2)

1463 BLK 17 Pin Connector H (MC82B) (3) 17 Pin Connector H (MC82A) (2)

1462 BLK 17 Pin Connector J (MC82B) (3) 17 Pin Connector J (MC82A) (2)

1435 BLK 17 Pin Connector K (MC82B) (3) Relay R52/Terminal 85 (8)

17 Pin Connector K (MC82A) (2)

1435 BLK 17 Pin Connector L (MC82B) (3) 10 Pin Connector A & E (MC185) (4)

17 Pin Connector L (MC82A) (2)

1471 BLK 17 Pin Connector M (MC82B) (3) 17 Pin Connector M (MC82A) (2)

1460 BLK 17 Pin Connector N (MC82B) (3) 17 Pin Connector N (MC82A) (2)

1459 BLK 17 Pin Connector P (MC82B) (3) 17 Pin Connector P (MC82A) (2)

1435 BLK 17 Pin Connector R (MC82B) (3) 17 Pin Connector R (MC82A) (2)

1435 BLK 17 Pin Connector S (MC82B) (3) 17 Pin Connector S (MC82A) (2)

1495 BLK Relay R50/Terminal 85 (6) Relay R52/Terminal 30 (8)

1464 BLK Relay R51/Terminal 30 (7) Relay R51/Terminal 86 (7)

1496 BLK Relay R51/Terminal 85 (7) Relay R52/Terminal 87 (8)
TM 9-2320-364-20-5

21-94

21-22. CONTAINER HANDLING UNIT (CHU) CONTROL BOX WIRING 

REPLACEMENT (CONT).

b. Installation.

NOTE

Connect only wires required to complete task. Refer to Table 21-2 CHU Control Box Wiring

for specific control box wiring replacement.

(1) Follow Table 21-2 to connect wires.

(2) Install connectors MC185 (4), MC82B (3) and MC82A (2) to control box (5) using three nuts (1).

c. Follow-On Maintenance:

• Install CHU control box assembly, (Para 21-21).

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

R52 R51 R50

8

7 6

5

4 3

2

1 1

1
TM 9-2320-364-20-5

 21-95

This task covers:

a. Disassembly b. Assembly c. Follow-On Maintenance

INITIAL SETUP

Materials/Parts

Lockwasher (2) (Item 171, Appendix F)

Lockwasher (2) (Item 175, Appendix F)

Equipment Condition

CHU control box wiring removed, (Para 21-22)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

21-23. CONTAINER HANDLING UNIT (CHU) CONTROL BOX REPAIR.

a. Disassembly.

(1) Remove relay R50 (1), R51 (2) and R52 (3)

from three relay socket modules (4).

3

2 1

4
TM 9-2320-364-20-5

21-96

21-23. CONTAINER HANDLING UNIT (CHU) CONTROL BOX REPAIR (CONT).

(2) Remove two screws (5), lockwashers (6),

relay mount bracket (7) and relay mount

spacer (8) from control box (9). Discard

lockwashers.

(3) Remove two screws (10), lockwashers (11),

washers (12) and relay mount spacer (4)

from relay mount bracket (7). Discard

lockwashers.

NOTE

Perform Step (4) if inserts are

damaged.

(4) Remove two inserts (13) from relay mount

bracket (7).

b. Assembly.

NOTE

Perform Step (1) if inserts were

removed.

(1) Install two inserts (13) in relay mount

bracket (7).

(2) Install three relay socket modules (4), two

washers (12), lockwashers (11) and screws

(10) to relay mount bracket (7).

(3) Install relay mount spacer (8), relay mount

bracket (7), two lockwashers (6) and screws

(5) to control box (9).

(4) Install relay R52 (3), R51 (2) and R50 (1) to

three relay socket modules (4).

c. Follow-On Maintenance:

• Install CHU box wiring, (Para 21-22).

END OF TASK

10

11 12

7

8

9

5

6 13

4

3

2 1

4
TM 9-2320-364-20-5

 21-97

This task covers:

a. Removal c. Adjustment

b. Installation d. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Clamp, Machinist (2) (Item 10, Appendix G)

Gage, Feeler (Item 27, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

21-24. CONTAINER HANDLING UNIT (CHU) PROXIMITY SWITCH AND SENSING 

PLATE REPLACEMENT/ADJUSTMENT (HOOK ARM UP).

Materials/Parts

Epoxy (Item 38, Appendix C)

Tags, Identification (Item 88, Appendix C)

Lockwasher (2) (Item 195, Appendix F)

References

TM 9-2320-364-10

TM 43-0139

a. Removal.

(1) Disconnect CHU proximity switch MC188 connector (1) from CHU wire harness (2).

1

2
TM 9-2320-364-20-5

21-98

21-24. CONTAINER HANDLING UNIT (CHU) PROXIMITY SWITCH AND SENSING 

PLATE REPLACEMENT/ADJUSTMENT (HOOK ARM UP) (CONT).

(2) Remove two nuts (3) and proximity switch

(4) from proximity switch mount (5).

(3) Remove two screws (6), lockwashers (7) and

proximity switch mount (5) from two clamp

halves (8). Discard lockwashers.

NOTE

Perform Step (4) if sensor plate is

damaged.

(4) Remove sensor plate (9) from LHS hook

arm (10).

b. Installation.

NOTE

• Perform Steps (1) through (20) if sensor plate was removed.

• LHS is being raised to expose area to install sensor plate.

(1) Start engine and stow LHS (TM 9-2320-364-10).

9

3

4

8

5 7

6

3

10
TM 9-2320-364-20-5

 21-99

Engine speed must be at idle

before using hydraulic selector

switch, or damage to equipment

may result.

(2) Set hydraulic selector switch (11) to

MAN H.A. and raise hook arm (12)

until hook arm cylinder pivot pin (13)

is 25 in. (63.5 cm) from main frame (14).

(3) Set hydraulic selector switch (11) to MAN

M.F. and raise main frame (14) until hook

arm cylinder pivot pin (13) is 45 in. (114.3

cm) from main frame (14).

(4) Shut OFF engine.

(5) Disconnect batteries (Para 7-87).

STEERING WHEEL

SHOWN REMOVED

FOR CLARITY

11

13

14

12
TM 9-2320-364-20-5

21-100

21-24. CONTAINER HANDLING UNIT (CHU) PROXIMITY SWITCH AND SENSING 

PLATE REPLACEMENT/ADJUSTMENT (HOOK ARM UP) (CONT).

(6) Measure and mark an area on hook arm (15) for sensor plate (9) to be mounted as shown.

CARC paint contains isocyanate (HDI) which is highly irritating to skin and respiratory

system. High concentrations of HDI can produce symptoms of itching and reddening of

skin, a burning sensation in throat and nose and watering of the eyes. In extreme

concentrations, HDI can cause cough, shortness of breath, pain during respiration, increased

sputum production, and chest tightness. The following precautions must be taken whenever

using CARC paint:

• ALWAYS use air line respirators when using CARC paint unless air sampling shows

exposure to be below standards. Use chemical cartridge respirator if air sampling is below

standards.

• DO NOT let skin or eyes come in contact with CARC paint. Always wear protective

equipment (gloves, ventilation mask, safety goggles, etc.).

• DO NOT use CARC paint without adequate ventilation.

• NEVER weld or cut CARC-coated materials.

• DO NOT grind or sand painted equipment without high-efficiency air purifying respirators 

in use.

• BE AWARE of CARC paint exposure symptoms; symptoms can occur a few days after 

initial exposure. Seek medical help immediately if symptoms are detected.

(7) Grind off paint in area marked in Step (6) for sensor plate (9) to be mounted.

(8) Mark hook arm (15) 2.59 in. (6.59 cm) from boss (16) on hook arm.

(9) Align sensor plate (9) .15 in. (3.81 mm) below top edge of hook arm (15).

9

15

2.59 IN.

(6.58 CM)

0.15 IN.

(3.81 MM)

16
TM 9-2320-364-20-5

 21-101

(10) Position sensor plate (9) with two clamps

on hook arm (15) as shown.

(11) Mark line around sensor plate (9) on hook

arm (15).

(12) Remove two clamps and sensor plate (9)

from hook arm (15).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

NOTE

Mix epoxy according to directions

on package.

(13) Mix epoxy and apply to sensor plate (9) and

hook arm (15).

NOTE

Epoxy takes approximately 15

minutes to cure.

(14) Clamp sensor plate (9) to hook arm (15) in

position marked until cured.

(15) Remove clamps from hook arm (15).

(16) Prime and paint area as necessary. (TM

43-0139).

9

15

CLAMPS
TM 9-2320-364-20-5

21-102

21-24. CONTAINER HANDLING UNIT (CHU) PROXIMITY SWITCH AND SENSING 

PLATE REPLACEMENT/ADJUSTMENT (HOOK ARM UP) (CONT).

(17) Measure and mark an area on hook arm

(15) for sensor plate (9) to be mounted.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(18) Using epoxy, mount sensor plate (9) and

clamp in place until cured (approximately 

15 minutes).

(19) Remove clamps from hook arm (15).

(20) Prime and paint area as necessary.

(21) Install two screws (6), lockwashers (7) and

proximity switch mount (5) on two clamp

halves (8).

(22) Install CHU proximity switch (4) and two

nuts (3) on proximity switch mount (5).

3

4

8

5 7

6

3

2.59 IN.

(6.58 CM)

0.15 IN.

(3.81 MM)

15

9

9

15

CLAMPS
TM 9-2320-364-20-5

 21-103

(23) Connect CHU proximity switch MC188

connector (1) on CHU wire harness (2).

c. Adjustment.

(1) Connect batteries, (Para 7-87).

(2) Start engine, set hydraulic selector switch (1)

to MAN H.A. and raise hook arm (2) until

sensor plate (3) covers approximately half of

proximity switch (4) 

(TM 9-2320-364-10).

(3) Shut OFF engine.

(4) Using feeler gage, adjust clearance between

CHU proximity switch (4) and sensor 

plate (3) to 0.125 in. ± 0.01 in. (3.18 mm ±

0.25 mm) and tighten nuts (5).

d. Follow-on Maintenance:

• Check operation of hook arm, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

1

2

3

4

5

2

1

STEERING

WHEEL SHOWN

REMOVED FOR CLARITY
TM 9-2320-364-20-5

21-104

21-25. CONTAINER HANDLING UNIT (CHU) MODE SWITCH REPLACEMENT/

ADJUSTMENT.

This task covers:

a. Removal c. Adjustment

b. Installation d. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Left slider in container mode,

(TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Materials/Parts

Locknut (2) (Item 103, Appendix F)

a. Removal.

(1) Disconnect MC189 connector (1) from CHU

wire harness (2).

1

2
TM 9-2320-364-20-5

 21-105

(2) Remove two screws (3), locknuts (4) and

mode switch (5) from left rear roller bracket

(6). Discard locknuts.

b. Installation.

(1) Install mode switch (5), two screws (3) and

locknuts (4) on left rear roller bracket (6).

Do not tighten locknuts.

(2) Connect MC189 connector (1) to CHU wire

harness (2).

c. Adjustment.

(1) Remove quick release pin (1) and pin (2)

from left side short strut (3) and long strut

(4).

(2) With the aid of an assistant and using handle

of arm assembly (5), rotate arm assembly out

and separate short strut (3) from long strut

(4).

(3) With the aid of an assistant holding arm

assembly (5), position flip lock (6) up.

3

4

5

6

1

2

3

1

4 2

6 5
TM 9-2320-364-20-5

21-106

21-25. CONTAINER HANDLING UNIT (CHU) MODE SWITCH REPLACEMENT/

ADJUSTMENT (CONT).

(4) Position long strut (4) half on stowage

bracket (7) and install pin (2) and quick

release pin (1).

(5) Using handle of arm assembly (5), rotate

arm assembly out and release flip lock (6).

(6) Position short strut (3) in stowed position on

stow plate (8).

(7) Push down handle (9) and stow slider

assembly (10) in forward position.

2

1

5

6

4

7

3 8

9 10
TM 9-2320-364-20-5

 21-107

(8) Measure distance between short strut (3) and

mode switch bracket (11).

NOTE

• If gap between short strut and

mode switch bracket is not

7/16 in. ± 1/16 in. (1.59 mm),

perform Step (9).

• If gap between short strut and

mode switch bracket is 7/16

in. ± 1/16 in. (1.59 mm), go

to Step (10).

(9) Position mode switch (12) to dimension

shown.

(10) Tighten two screws (13) and lock nuts (14)

on mode switch (12) and rear roller bracket

(15).

(11) Deploy left arm assembly (TM 9-2320-364-10).

d. Follow-on Maintenance:

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

11

3

13 14

15

12

7/16 IN. ± 1/16 IN.

(11.11 MM ± 1.59 MM)
TM 9-2320-364-20-5

21-108

21-26. CONTAINER HANDLING UNIT (CHU) REAR LOCK LIMIT SWITCH 

REPLACEMENT/ADJUSTMENT.

This task covers:

a. Removal c. Adjustment

b. Installation d. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Sliders in container mode, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Materials/Parts

Cable ties (Item 25, Appendix C)

Sealing Compound (Item 77, Appendix C)

a. Removal.

NOTE

• Note routing of switch wire

harness prior to removal.

• Remove required cable ties.

• Left and right lock limit

switches are identical. Right

lock limit switch is shown.

(1) Disconnect MC190 connectors (1) from

CHU wire harness connectors (2).

1

2
TM 9-2320-364-20-5

 21-109

(2) Remove three screws (3), washers (4) and cushion clips (5) from CHU wire harness (6) and arm 

assembly (7).

(3) Remove screw (8) and cushion clip (9) from CHU wire harness (6) and slider (10).

(4) Remove two screws (11) and lock limit switch (12) from slider (10).

b. Installation.

NOTE

• Left and right lock limit switches are identical. Right lock limit switch is shown.

• Install cable ties as required.

(1) Position lock limit switch (12) with two screws (11) on slider (10). Do not tighten screws.

Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors,

and are harmful to skin and clothing. To avoid injury or death, keep away from open fire

and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or

clothing, wash immediately with soap and water.

(2) Apply sealing compound to threads of screw (8).

(3) Position cushion clip (9) on CHU wire harness (6) and install on slider (10) with screw (8).

4

12

10

9

8

7

5

11

3

6

6
TM 9-2320-364-20-5

21-110

21-26. CONTAINER HANDLING UNIT (CHU) REAR LOCK LIMIT SWITCH 

REPLACEMENT/ADJUSTMENT (CONT).

(4) Stow right slider (TM 9-2320-364-10).

(5) Position CHU wire harness (6) along 

arm assembly (7) and under rear roller

assembly (13).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(6) Apply sealing compound to threads of three

screws (3).

Ensure there is enough slack in

wire harness to rotate arm

assembly without causing harness

to stretch.

(7) Position three cushion clips (5) on CHU wire

harness (6) and install on arm assembly (7)

with three screws (3) and washers (4).

(8) Connect MC190 connector (1) to CHU wire

harness connectors (2).

1

2

4

7

5 3

6

13
TM 9-2320-364-20-5

 21-111

c. Adjustment.

(1) Position slider in container mode 

(TM 9-2320-364-10).

(2) Raise LHS in AUTO mode approximately

18 inches (46 cm). Release joy stick (1).

NOTE

• Both rear container locks are

installed the same way. Left

side shown.

• Lock handle is unlocked

when facing front of slider.

(3) Turn lock handle (2) on left rear slider

assembly (3) forward to unlocked position.

(4) Remove lock pin (4), pin (5) and rear

container lock (6) from lifting frame (7).

(5) Position rear container lock (6) in locked

position on left rear slider assembly (3) and

install pin (5) and lock pin (4).

(6) Turn lock handle (2) on left rear slider

assembly (3) back to locked position.

NOTE

• LHS should not move when

joystick is in unload position.

• If LHS does not move in

unload position, go to Step

(14).

• If LHS moves in unload

position, perform Steps (8)

through (12).

(7) Move joystick (1) to UNLOAD position

and check LHS for movement.

STEERING WHEEL

SHOWN REMOVED

FOR CLARITY

1

2

3

4

5

6

5

4 6

7
TM 9-2320-364-20-5

21-112

21-26. CONTAINER HANDLING UNIT (CHU) REAR LOCK LIMIT SWITCH 

REPLACEMENT/ADJUSTMENT (CONT).

(8) Position container lock (6) in locked position

and install pin (5) and lock pin (4).

(9) Remove two screws (8) from lock limit

switch (9).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(10) Apply sealing compound to threads of two

screws (8).

(11) Position lock limit switch (9) with two

screws (8) on slider.

NOTE

Lock limit switch is properly

adjusted when lever is depressed

and lock limit switch makes an

audible click.

(12) Position lock limit switch (9) against

container lock (6) until audible click is heard

and tighten two screws (8).

(13) Repeat Step (7) to check LHS for movement.

4 5 6

9

8

8
TM 9-2320-364-20-5

 21-113

Container lock could drop

suddenly if not supported. Failure

to comply may result in injury to

personnel.

(14) Support rear container lock (6) and remove

lock pin (4) and pin (5) from rear container

lock.

(15) Position and lock rear container lock (6) in

ready mode position by pulling out, rotating

down, and inserting pin (5) and lock pin (4).

(16) Repeat Steps (3) through (15) for right side

of truck.

d. Follow-on Maintenance:

• Connect batteries, (Para 7-87).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

4

5

6

4 5

6
TM 9-2320-364-20-5

21-114

21-27. CONTAINER HANDLING UNIT (CHU) LIGHT BAR AND BRACKETS 

ASSEMBLY REPAIR.

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Materials/Parts

Cable Ties (Item 25, Appendix C)

Compound, Corrosive Preventive 

(Item 34, Appendix C)

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Batteries disconnected, (Para 7-87)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Materials/Parts (cont)

Silicone Compound, Anti-Corrosion

(Item 85, Appendix C)

Locknut (18) (Item 103, Appendix F)

Lockwasher (12) (Item 168, Appendix F)

a. Removal.

NOTE

Connectors are removed by gently prying on tab and pulling apart.

(1) Disconnect MC90 connector (1).

1
TM 9-2320-364-20-5

 21-115

NOTE

• There are seven red marker

lights. All red marker lights

are removed the same way.

• Remove cable ties as

required.

• Loop clamp is removed by

first pulling out lock button

and then removing loop

clamp.

• Note position of wires and

ground wires prior to

removal.

(2) Remove push clip (2) and two wires 489 (3)

from rear light bar assembly (4).

(3) Disconnect wire 1012 (5) from wire 489 (3).

NOTE

• Perform Steps (4) through (6)

for marker light with lamp.

• Perform Steps (7) through (9)

for marker light with LED.

(4) Remove two screws (6) and lens cover (7)

from marker light assembly (8).

(5) Remove marker lamp (9) from marker lamp

socket (10).

(6) Remove two locknuts (11), wire 1435 (12),

two screws (13), marker light assembly (8)

and gasket (14) from marker light bracket

(15). Discard locknuts.

7 6

8

9

10

11

3

13

14

15

2

3

4

5

3

12
TM 9-2320-364-20-5

21-116

21-27. CONTAINER HANDLING UNIT (CHU) LIGHT BAR AND BRACKETS 

ASSEMBLY REPAIR (CONT).

(7) Remove two screws (16) and lens cover (17)

from marker light assembly (18).

(8) Remove two locknuts (19), wire 489 (20),

ground wire (21), two screws (22), ground

wire (23) marker light assembly (18) and

gasket (24) from marker light bracket (25).

Discard locknuts.

(9) Turn LED (26) counterclockwise 1/4 turn

and remove from marker light assembly

(18).

(10) Support marker light bracket (25), remove

two nuts (27), lockwashers (28) and marker

light bracket (25) from rear roller brackets

(29). Discard lockwashers.

(11) Remove two nuts (30), lockwashers (31)

and mounts (32) from marker light bracket

(25). Discard lockwashers.

NOTE

Both marker light brackets are

removed the same way.

(12) Repeat Steps (10) and (11) for left side of

truck.

16

17

18

19

20

22

23

24

25

26

27

28

29

25

32

30

31

21
TM 9-2320-364-20-5

 21-117

Use care when removing bracket to prevent wires from being damaged.

NOTE

• Perform Step (13) for both sides of rear light bar assembly.

• Lift and tilt bracket to remove mounts.

(13) Remove two nuts (33), lockwashers (34), mount (35), and rear light bar assembly (4) from right rear roller

bracket (36). Discard lockwashers.

33

34

35

36

4

33

34
TM 9-2320-364-20-5

21-118

21-27. CONTAINER HANDLING UNIT (CHU) LIGHT BAR AND BRACKETS 

ASSEMBLY REPAIR (CONT).

b. Disassembly.

Use care when removing bracket

to prevent wires from being

damaged.

NOTE

• Perform Step (1) for both

sides of rear light bar

assembly.

• Note position of wires and

ground wires prior to

disassembly.

(1) Disconnect wire 1680 (1) from wire 490 (2).

(2) Remove two screws (3) from blackout lens

cover (4).

(3) Remove blackout lamp (5) from blackout

lamp socket (6).

(4) Remove two screws (7), locknuts (8), ground

wire (9), blackout light assembly (10) and

gasket (11) from rear light bar assembly

(12). Discard locknuts.

c. Cleaning and Inspection.

(1) Inspect all wires and connectors for damage.

(2) Inspect bulbs, LEDs and lens for cracks.

(3) Inspect all other parts for cracks or other

damage.

(4) Replace all damaged parts. If entire marker

light assembly is being replaced, new marker

light assembly will be a LED.

1 2

4

3

5

6

7

8

10

11

12

9
TM 9-2320-364-20-5

 21-119

d. Assembly.

Keep all moisture and oils off

lamp. Do not touch lamp with

bare hands. Use a clean dry, oil

free cloth to hold lamp while

installing lamp in blackout light.

NOTE

• There are two blackout lights.

Both blackout lights are

installed the same way.

• Install cable ties as required.

• Install ground wire as noted

prior to removal.

(1) Install gasket (11), blackout light assembly

(10), two screws (7), ground wire (9) and

two locknuts (8) on rear light bar assembly

(12).

Corrosion inhibitor contains

alkali. Do not get in eyes; wear

goggles/safety glasses when

using. Avoid contact with skin.

In case of contact, immediately

wash area with soap and water. If

eyes are contacted, flush eyes

with large amounts of water for at

least 15 minutes and get

immediate medical attention.

(2) Apply anti-corrosion inhibitor silicone

compound to inside of lamp socket (6).

(3) Install blackout lamp (5) in blackout lamp

socket (6).

(4) Install lens cover (4) with two screws (3) in

blackout light assembly (10).

(5) Connect wire 1680 (1) to wire 490 (2).

(6) Apply corrosive preventive compound to

ground wire (9).

1 2

4

3

5

6

7

8

10

11

12

9
TM 9-2320-364-20-5

21-120

21-27. CONTAINER HANDLING UNIT (CHU) LIGHT BAR AND BRACKETS 

ASSEMBLY REPAIR (CONT).

e. Installation.

NOTE

• Perform Step (1) for both

sides of rear light bar

assembly.

• Install ground wire as noted

prior to removal.

• Both marker light brackets

are installed the same way.

Right side is shown.

(1) Install mount (35), two lockwashers (34),

nuts (33) and rear marker light assembly (4)

in right rear roller bracket (36).

(2) Install two mounts (32) on marker light

bracket (25) with two lockwashers (31) and

nuts (30).

(3) Install marker light bracket (25) with two

lockwashers (28) and nuts (27) on rear roller

brackets (29).

(4) Repeat Steps (2) and (3) for left side of

truck.

33

34

35

36

4

33

34

27

28

29

25

32

30

31
TM 9-2320-364-20-5

 21-121

NOTE

• All seven red marker lights

are installed the same way.

• Perform Steps (5) through (8)

for rear marker light with

lamp.

• Perform Steps (10) through

(14) for rear marker light

with LED.

(5) Install gasket (14), marker light assembly

(8), two screws (13), wire 1435 (12) and two

locknuts (11) on marker light bracket (15).

Corrosion inhibitor contains

alkali. Do not get in eyes; wear

goggles/safety glasses when

using. Avoid contact with skin.

In case of contact, immediately

wash area with soap and water. If

eyes are contacted, flush eyes

with large amounts of water for at

least 15 minutes and get

immediate medical attention.

(6) Apply anti-corrosion silicone compound to

inside of rear lamp socket (10).

(7) Install lamp (9) in lamp socket (10).

(8) Install lens cover (7) with two screws (6) in

light assembly (8).

(9) Apply corrosive preventive compound to

wire 1435 (12).

7 6

8

9

10

11

13

14

15

12
TM 9-2320-364-20-5

21-122

21-27. CONTAINER HANDLING UNIT (CHU) LIGHT BAR AND BRACKETS 

ASSEMBLY REPAIR (CONT).

(10) Position ground wire (23) through hole in

marker light assembly (18).

(11) Install LED (26) in marker light assembly

(18) and turn 1/4 turn clockwise.

(12) Install gasket (24), marker light assembly

(18), two screws (22), ground wire (23),

ground wire (21), wire 489 (20) and two

locknuts (19) on marker light bracket (25).

(13) Install lens cover (17) with two screws (16)

on marker light assembly (18).

Corrosion inhibitor contains

alkali. Do not get in eyes; wear

goggles/safety glasses when

using. Avoid contact with skin.

In case of contact, immediately

wash area with soap and water. If

eyes are contacted, flush eyes

with large amounts of water for at

least 15 minutes and get

immediate medical attention.

(14) Apply corrosive preventive compound to

ground wire (21).

(15) Connect wire 1012 (5) to wire 489 (3).

(16) Install push clip (2) and two wires 489 (3)

on rear marker light assembly (4).

(17) Connect MC90 connector (1).

f. Follow-On Maintenance:

• Connect batteries, (Para 7-87).

• Check operation of rear marker light 

assembly, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

2

3

4

5

3

16

17

18

19

20

22

23

24

25

26 21

1
TM 9-2320-364-20-5

 21-123

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective 

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

21-28. CONTAINER HANDLING UNIT (CHU) CONTAINER GUIDE REPAIR.

a. Removal.

NOTE

• If CHU is in container mode,

perform Step (1). If CHU is

in flatrack mode, perform

Step (2).

• There are two container

guides. Left and right side

are removed the same way.

Left side is shown.

(1) Remove two lock pins (1) and container

guide (2) from slider (3).

1

3

2

1
TM 9-2320-364-20-5

21-124

21-28. CONTAINER HANDLING UNIT (CHU) CONTAINER GUIDE REPAIR (CONT).

(2) Remove lock pin (4), pin (5) and container guide (2) from stow bracket (6).

b. Disassembly.

NOTE

• Perform Step (1) if wire rope

or lock pin is damaged.

• There are two lock pins on

container guide. Left side is

shown.

(1) Remove two swaging sleeves (1), wire rope

(2) and lock pin (3) from container guide (4).

Discard wire rope and swaging sleeves. 2

1

6

5

4 2

3

1

4
TM 9-2320-364-20-5

 21-125

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

(1) Clean all metal parts with drycleaning solvent.

Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.) or

injury to personnel may result.

(2) Dry parts with compressed air.

(3) Inspect parts for breaks, cracks, burrs and sharp edges. Look for unusual signs of wear on container guide.

(4) Replace all damaged parts.

d. Assembly.

NOTE

• Perform Step (1) if wire rope

or lock pin were removed.

• There are two lock pins on

container guide. Left side is

shown.

(1) Install wire rope (2), swaging sleeves (1) and

lock pin (3) on container guide (4).

2

1

3

1

4
TM 9-2320-364-20-5

21-126

21-28. CONTAINER HANDLING UNIT (CHU) CONTAINER GUIDE REPAIR (CONT).

e. Installation.

NOTE

• If CHU is in flatrack mode,

perform Step (1). If CHU is

in container mode, perform

Step (2).

• Installation of left and right

side container guides is the

same. Left side is shown.

(1) Install container guide (2) with pin (5) and

lock pin (4) on stow bracket (6).

(2) Install container guide (2) on slider (3) with

two lock pins (1).

f. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

6

5

4 2

1

3

2

1
TM 9-2320-364-20-5

 21-127

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Materials/Parts

Grease (Item 41, Appendix C)

Sealing Compound (Item 77, Appendix C)

Sealing Compound (Item 83, Appendix C)

Pin, Cotter (2) (Item 267, Appendix F)

Pin, Roll (Item 279, Appendix F)

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Limit switch removed, (Para 21-26)

Slider in container mode, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

Lifting Device, Minimum Capacity

140 lbs (64 kg)

Pliers, Retaining Ring (Item 49, Appendix G)

21-29. CONTAINER HANDLING UNIT (CHU) SLIDER/PIVOT ASSEMBLY REPAIR.

Materials/Parts (cont)

Locknut (10) (Item 96, Appendix F)

Locknut (2) (Item 140, Appendix F)

Screw, Self-Tapping (2) (Item 314, Appendix F)

Seal (2) (Item 320, Appendix F)

Personnel Required

Two
TM 9-2320-364-20-5

21-128

21-29. CONTAINER HANDLING UNIT (CHU) SLIDER/PIVOT ASSEMBLY 

REPAIR (CONT).

a. Removal.

NOTE

• Left side and right side

slider/pivot assembly are

identical unless noted.

• Right side slider/pivot

assembly is shown.

Slider weighs 142 lbs (64 kg).

Attach suitable lifting device to

prevent possible injury to

personnel.

(1) Attach lifting device to slider assembly (1).

Use care when removing snap

and retaining rings. Snap and

retaining rings are under spring

tension and can act as projectiles

when released and could cause

severe eye injury.

(2) Remove retaining ring (2) and spacer (3)

from pivot pin (4) and slider assembly (1).

Discard retaining ring.

(3) With the aid of an assistant, remove slider

assembly (1) from arm assembly (5).

(4) Position slider assembly (1) on clean work

surface and remove lifting device.

1

2

3

4

5
TM 9-2320-364-20-5

 21-129

b. Disassembly.

Use care when removing snap

and retaining rings. Snap and

retaining rings are under spring

tension and can act as projectiles

when released and could cause

severe eye injury.

(1) With the aid of an assistant, remove retaining

ring (1), pivot pin (2), spacer (3) and slider

pivot (4) from slider (5).

NOTE

Note position of torsion spring

prior to removal.

(2) Remove locknut (6) from screw (7). Discard

locknut.

Use care when removing springs.

Springs are under tension and can

act as projectiles when released

and could cause injury to

personnel.

(3) Push in on end of torsion spring (8) and

remove screw (7) from slider pivot (4).

(4) Remove locknut (9), screw (10), torsion

spring (8) and pivot lock arm (11) from

slider pivot (4). Release torsion spring and

discard locknut.

(5) Remove two cotter pins (12), washers (13),

pivot lock slot pin (14) and pivot lock pin

(15) from pivot lock arm (11). Discard cotter

pins.

5

1

2

3

4

10

9

13

8

11

14 15

12

6

7

11

13

4

12
TM 9-2320-364-20-5

21-130

21-29. CONTAINER HANDLING UNIT (CHU) SLIDER/PIVOT ASSEMBLY 

REPAIR (CONT).

(6) Remove two grease fittings (16) from slider

pivot (4).

(7) Remove two seals (17) from slider pivot (4).

Discard seals.

(8) Remove ten socket head screws (18),

locknuts (19) and wear plate (20) from slider

(5). Discard locknuts.

(9) Remove two self-tapping screws (21),

reflector (22) and reflector housing (23)

from slider (5). Discard self-tapping screws.

(10) Remove grease fitting (24) from slider (5).

(11) Remove roll pin (25), handle (26), spring

(27) and pin (28) from slider (5). Discard

roll pin.

18

19

20

5

4

23

21

16

22

25

26 27 28

24

5

17

17
TM 9-2320-364-20-5

 21-131

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

(1) Clean all metal parts with drycleaning solvent.

Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.) or

injury to personnel may result.

(2) Dry parts with compressed air.

(3) Inspect parts for breaks, cracks, burrs and sharp edges. Look for unusual signs of wear on slider.

(4) Replace all damaged parts.

d. Assembly.

(1) Install spring (27), pin (28), handle (26) and

roll pin (25) on slider (5).

(2) Install grease fitting (24) on slider (5).

25

26 27 28

24

5
TM 9-2320-364-20-5

21-132

21-29. CONTAINER HANDLING UNIT (CHU) SLIDER/PIVOT ASSEMBLY 

REPAIR (CONT).

(3) Install reflector housing (23), reflector (22)

and two self-tapping screws (21) on slider

(5).

(4) Position wear plate (20) on slider (5) and

install ten socket head screws (18) and

locknuts (19).

NOTE

Seals must be installed with open

groove to the outside.

(5) Install two seals (17) in slider pivot (4).

(6) Install two grease fittings (16) in slider pivot

(4).

17

GROOVE

18

19

20

5

23

21

22

4

16

17

17
TM 9-2320-364-20-5

 21-133

(7) Install pivot lock pin (15), pivot lock slot pin

(14), two washers (13) and cotter pins (12)

on pivot lock arm (11).

NOTE

Ensure torsion spring is installed

as noted prior to removal.

(8) Install pivot lock arm (11), torsion spring

(8), screw (10) and locknut (9) in slider

pivot (4).

(9) Push in on end of torsion spring (8) and

install screw (7) and locknut (6) in slider

pivot (4).

10

9

8

11

6

7

4

10 14

7

13 14 15

12 11

13

12

END OF 

TORSION

SPRING
TM 9-2320-364-20-5

21-134

21-29. CONTAINER HANDLING UNIT (CHU) SLIDER/PIVOT ASSEMBLY 

REPAIR (CONT).

NOTE

Ensure end of pivot pin aligns

with stud on slider during

installation.

(10) With the aid of an assistant, position slider

pivot (4) in slider (5) and install spacer (3),

pivot pin (2) and retaining ring (1).

e. Installation.

Slider weights 142 lbs (64 kg).

Attach suitable lifting device to

prevent possible injury to

personnel.

(1) Attach lifting device to slider assembly (1).

(2) Apply light coat of grease to outer surface of

slider pivot pin (4), washer (3) and retaining

ring (2).

5

1

2

3

4

1

2

3

4
TM 9-2320-364-20-5

 21-135

NOTE

Ensure retaining ring is fully

seated in Step (3).

(3) With the aid of an assistant, position slider

pivot pin (4) in arm assembly (5) and install

washer (3) and retaining ring (2). 

(4) Remove lifting device from slider assembly

(1).

(5) Check that pivot lock pin (6) properly locks

into handle (7).

NOTE

If pivot lock pin does not

properly lock into handle perform

Steps (6) through (10).

(6) Remove four screws (8), shim(s) (9) (if

present) and handle (7) from arm assembly

(5).

(7) Remove or add shim(s) (9) to arm assembly

(5) as required.

Adhesives, solvents, and sealing

compounds can burn easily, can give

off harmful vapors, and are harmful

to skin and clothing. To avoid injury

or death, keep away from open fire

and use in well-ventilated area. If

adhesive, solvent, or sealing

compound gets on skin or clothing,

wash immediately with soap and

water.

(8) Apply sealing compound (loctite 242) to

threads of four screws (8).

1

2

3

4

5

6

7

5

8

7

9
TM 9-2320-364-20-5

21-136

21-29. CONTAINER HANDLING UNIT (CHU) SLIDER/PIVOT ASSEMBLY 

REPAIR (CONT).

(9) Install four screws (8), handle (7) and

shim(s) (9) (as required) on right arm

assembly (5).

(10) Repeat Step (5).

f. Follow-On Maintenance:

• Install limit switch, (Para 21-26).

• Lubricate CHU slider/pivot assembly, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

5

8

7

9
TM 9-2320-364-20-5

 21-137

21-30. CONTAINER HANDLING UNIT (CHU) SHORT STRUT AND PIN BRACKET 

ASSEMBLY REPAIR.

This task covers:

a. Removal d. Assembly f. Adjustment

b. Disassembly e. Installation g. Follow-On Maintenance

c. Cleaning/Inspection

INITIAL SETUP

Materials/Parts

Antiseize Compound (Item 21, Appendix C)

Sealing Compound (Item 83, Appendix C)

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Slider arm in container mode,

(TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective 

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

Pliers, Retaining Ring (Item 49, Appendix G)

Personnel Required

Two

a. Removal.

NOTE

• There are two pin bracket

assemblies. Both are

removed the same way.

Right side is shown.

• Do not support slider arm

with flip lock.

(1) With the aid of an assistant, remove quick

release pin (1) and pin (2) from short strut

(3) and long strut (4).

(2) With the aid of an assistant, rotate slider arm

(5) toward front of truck.

Use care when removing springs.

Springs are under tension and can

act as projectiles when released

and could cause injury to

personnel.

(3) Unhook spring (6) from wire (7).

1

2 3

5

6

7

4
TM 9-2320-364-20-5

21-138

21-30. CONTAINER HANDLING UNIT (CHU) SHORT STRUT AND PIN BRACKET 

ASSEMBLY REPAIR (CONT).

Use care when removing snap

and retaining rings. Snap and

retaining rings are under spring

tension and can act as projectiles

when released and could cause

severe eye injury.

(4) Remove retaining ring (8) and ring support

(9) from short strut (3). 

(5) Remove short strut (3) and spacer (10) from

pin bracket (11).

(6) Remove four screws (12) and pin bracket

(11) from arm assembly (13).

b. Disassembly.

NOTE

Perform Steps (1) through (5)

only if components are damaged.

(1) Remove screw (1), washer (2), washer (3)

and spring (4) from short strut (5).

(2) Remove grease fitting (6) from short strut

(5).

(3) Remove retaining ring (7), spacer (8) and

bearing (9) from short strut (5).

11

3

8

9

13

11

10

1 2

3

6

9

4 5

8

7

12
TM 9-2320-364-20-5

 21-139

(4) Remove screw (10) and jam nut (11) from

flip lock (12).

(5) Remove roll pin (13), pin (14) and flip lock

(12) from pin bracket (15). 

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

(1) Clean all metal parts with drycleaning solvent.

Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.) or

injury to personnel may result.

(2) Dry parts with compressed air.

(3) Inspect parts for breaks, cracks, burrs and sharp edges. Look for unusual signs of wear on short strut.

(4) Replace all damaged parts.

14

13

15

10

11

12
TM 9-2320-364-20-5

21-140

21-30. CONTAINER HANDLING UNIT (CHU) SHORT STRUT AND PIN BRACKET 

ASSEMBLY REPAIR (CONT).

d. Assembly.

NOTE

Perform Steps (1) through (7)

only if components were

removed.

(1) Install flip lock (12) to pin bracket (15) with

roll pin (13) and pin (14).

(2) Position jam nut (11) on screw (10) and

install screw (10) on flip lock (12). Do not

tighten nut.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(3) Apply a light coat of antiseize to outer

surface of bearing (9).

(4) Install bearing (9), spacer (8) and retaining

ring (7) in short strut (5).

(5) Install grease fitting (6) in short strut (5).

(6) Apply sealing compound to threads of screw

(1).

(7) Install spring (4), washer (3), washer (2) and

screw (1) on short strut (5).

14

13

15

10

11

12

1 2

3

6

9

4 5

8

7
TM 9-2320-364-20-5

 21-141

e. Installation.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

NOTE

There are two pin bracket

assemblies. Both are installed the

same way. Right side is shown.

(1) Apply sealing compound to threads of four

screws (12).

(2) Install four screws (12) and pin bracket (11)

on arm assembly (13).

Use care when installing snap and

retaining rings. Snap and

retaining rings are under spring

tension and can act as projectiles

when released and could cause

severe eye injury.

NOTE

Beveled edge of spacer faces

bearing in short strut.

(3) Install ring support (9), spacer (10), short

strut (3) and retaining ring (8) on pin bracket

(11).

(4) Hook spring (6) on wire (7).

(5) With the aid of an assistant, support slider

arm (5) and position short strut (3) in long

strut (4) and install pin (2) and quick release

pin (1).

12

13

11

11

3

8

9

10

1

2 3

5

6

7

4
TM 9-2320-364-20-5

21-142

21-30. CONTAINER HANDLING UNIT (CHU) SHORT STRUT AND PIN BRACKET 

ASSEMBLY REPAIR (CONT).

f. Adjustment.

NOTE

• Ensure slider arm is

deployed.

• Both flip lock brackets are

adjusted the same way. Right

side shown.

(1) Remove quick release pin (1) and pin (2)

from short strut (3) and long strut (4).

(2) With the aid of an assistant and using handle

of arm assembly (5), rotate arm assembly out

and separate short strut (3) from long strut

(4).

(3) With assistant holding arm assembly (5) out,

position flip lock (6) up.

(4) Measure gap between stop bolt (7) and right

rear roller bracket (8).

NOTE

• If gap is not 3/8 in. ± 1/8 in.

(9.5 mm ± 3.2 mm), perform

Steps (5) and (6).

• If gap is 3/8 in. ± 1/8 in. (9.5

mm ± 3.2 mm), go to Step

(8).

• If dimension of gap is greater

than 1.25 in. (3.18 cm)

following adjustment or

proper adjustment can not be

done, replace stop bolt with

2.50 in. (6.35 cm) long stop

bolt.

(5) Loosen jam nut (9) and adjust stop 

bolt (7) as required.

(6) Tighten jam nut (9) on stop bolt (7).

(7) If proper adjustment could not be made

repeat Steps (3) through (6) using longer

bolt.

3

1

2 4

6

5

5

8

9 6 7

3/8 IN. ± 1/8 IN.

(9.5 MM ± 3.2 MM)

1-1/8 IN. MAX WITH

1-3/4 IN. BOLT

1-5/8 IN. MAX WITH

2-1/2 IN. BOLT
TM 9-2320-364-20-5

 21-143

(8) Align long strut (4) with short strut (3).

(9) Using handle of arm assembly (5), rotate

arm assembly out and release flip lock (6).

(10) Position long strut (4) into short strut (3) 

and install pin (2) and quick release pin (1).

(11) Repeat Steps (1) through (10) for left side.

g. Follow-On Maintenance:

• Lubricate rear slider arm, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

3

1

2 4

6

5
TM 9-2320-364-20-5

21-144

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly f. Follow-On Maintenance

INITIAL SETUP

Materials/Parts

Adhesive (Item 2, Appendix C)

Grease (Item 41, Appendix C)

Sealing Compound (Item 73, Appendix C)

Sealing Compound (Item 77, Appendix C)

Equipment Condition

Wheels chocked, (TM 9-2320-364-10)

Engine OFF, (TM 9-2320-364-10)

Slider/Pivot assembly removed, (Para 21-29)

Pin bracket assembly removed, (Para 21-30)

Horizontal roller removed, (Para 15-15)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective 

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

Lifting Device, Minimum Capacity

240 lbs. (109 kg)

Pliers, Retaining Ring (Item 49, Appendix G)

21-31. CONTAINER HANDLING UNIT (CHU) SLIDER ARM ASSEMBLY REPAIR.

Materials/Parts (cont)

Sealing Compound (Item 79, Appendix C)

Preformed Packing (Item 238, Appendix F)

Preformed Packing (Item 239, Appendix F)

Seal (Item 322, Appendix F)

Seal (Item 323, Appendix F)

Personnel Required

Two
TM 9-2320-364-20-5

 21-145

a. Removal.

Arm assembly weighs 240 lbs

(109 kg). Attach suitable lifting

device to prevent possible injury

to personnel.

NOTE

There are two arm assemblies.

Both are removed the same way.

Right side is shown.

(1) Attach lifting device to arm assembly (1).

Use care when removing snap

and retaining rings. Snap and

retaining rings are under spring

tension and can act as projectiles

when released and could cause

severe eye injury.

NOTE

Note quantity of shims prior to

removal.

(2) Remove retaining ring (2), pivot pin (3) and

shim(s) (4) from rear roller bracket (5) and

arm assembly (1).

(3) With the aid of an assistant, remove arm

assembly (1) from rear roller bracket (5).

(4) Position arm assembly (1) on clean work

surface and remove lifting device.

4

2

5

3

1

4
TM 9-2320-364-20-5

21-146

21-31. CONTAINER HANDLING UNIT (CHU) SLIDER ARM ASSEMBLY REPAIR (CONT).

b. Disassembly.

(1) Remove seal (1), thrust washer (2) and

preformed packing (3) from large end of arm

assembly (4). Discard seal and preformed

packing.

(2) Remove seal (5), preformed packing (6) and

thrust washer (7) from small end of arm

assembly (4). Discard seal and preformed

packing.

1

2

3

5

6

7

4

4
TM 9-2320-364-20-5

 21-147

NOTE

Note quantity of shim(s) for

assembly.

(3) Remove four screws (8), handle (9) and

shim(s) (10) from arm assembly (4).

(4) Remove grease fittings (11) and grease

fitting (12) from arm assembly (4).

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

(1) Clean all metal parts with drycleaning solvent.

Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.) or

injury to personnel may result.

(2) Dry parts with compressed air.

(3) Inspect parts for breaks, cracks, burrs and sharp edges. Look for unusual signs of wear on arm.

(4) Replace all damaged parts.

8

9

11

4

12

10
TM 9-2320-364-20-5

21-148

21-31. CONTAINER HANDLING UNIT (CHU) SLIDER ARM ASSEMBLY REPAIR (CONT).

d. Assembly.

(1) Install grease fitting (11) and grease fitting

(12) in arm assembly (4).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(2) Apply sealing compound to threads of four

screws (8).

NOTE

Install quantity of shim(s) as

noted during disassembly.

(3) Install handle (9) and shim(s) (10) with four

screws (8) on arm assembly (4).

NOTE

Sealing compound is applied to

metallic side of thrust washer.

(4) Apply sealing compound (loctite 680) to

thrust washer (7).

(5) Apply adhesive (loctite 409) to six points in

recessed groove for preformed packing (6).

NOTE

Thrust washer is properly

installed with metallic side to arm

assembly.

(6) Install thrust washer (7), preformed packing

(6) and seal (5) in arm assembly (4).

5

6

7

4

8

9

11

4

12

10
TM 9-2320-364-20-5

 21-149

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

NOTE

Sealing compound is applied to

metallic side of thrust washer.

(7) Apply sealing compound (loctite 680) to

thrust washer (2).

(8) Apply adhesive (loctite 409) to six points in

recessed groove for preformed packing (3).

NOTE

Thrust washer is properly

installed with metallic side to arm

assembly.

(9) Install preformed packing (3), thrust washer

(2) and seal (1) on assembly (4).

2

3

1
TM 9-2320-364-20-5

21-150

21-31. CONTAINER HANDLING UNIT (CHU) SLIDER ARM ASSEMBLY REPAIR (CONT).

e. Installation.

(1) Apply grease to face of thrust washer, seal,

bore in arm assembly (1), and bores and

thrust face of rear roller bracket (5).

Arm assembly weighs 240 lbs

(109 kg). Attach suitable lifting

device to prevent possible injury

to personnel.

(2) Attach lifting device to arm assembly (1).

Ensure not to damage bottom of

preformed packing during arm

installation.

(3) With the aid of an assistant, position large

end of arm assembly (1) in rear roller

bracket (5).

Use care when installing snap and

retaining rings. Snap and

retaining rings are under spring

tension and can act as projectiles

when released and could cause

severe eye injury.

NOTE

Install amount of shims as noted

prior to removal.

(4) Apply grease to outer surface of pivot pin (3)

and install pivot pin, shim(s) (4) and

retaining ring (2) in arm assembly (1) and

rear roller bracket (5).

(5) Remove lifting device from arm assembly

(1).

4

2

5

3

1

4
TM 9-2320-364-20-5

 21-151

f. Follow-On Maintenance:

• Install horizontal roller, (Para 15-15).

• Install pin bracket assembly, (Para 21-30).

• Install slider/pivot assembly, (Para 21-29).

• Lubricate slider arm, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

21-152

21-32. CONTAINER HANDLING UNIT (CHU) REAR BRACKET ASSEMBLY 

REPLACEMENT.

This task covers:

a. Removal c. Adjustment d. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Slider removed, (Para 21-29)

Slider arm removed, (Para 21-31)

Hard lift strut removed, (Para 15-8)

Light bar and brackets removed, (Para 21-27)

Rear splash guard assembly removed,

(Para 17-39)

Horizontal roller removed, (Para 15-15)

Angled roller removed, (Para 15-16)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Lifting Device, Minimum Capacity,

150 lbs (68 kg)

Materials/Parts

Sealing Compound (Item 82, Appendix C)

Locknut (2) (Item 91, Appendix F)

Locknut (16) (Item 93, Appendix F)

(left side only)

Locknut (17) (Item 93, Appendix F)

(right side only)

Locknut (2) (Item 101, Appendix F)

Personnel Required

Two

a. Removal.

Rear roller bracket weighs 150 lbs (68 kg). When removing one rear roller bracket, ensure

remaining rear roller bracket is supported. Attach suitable lifting device to prevent possible

injury to personnel.

NOTE

• Right rear roller bracket and left rear roller bracket are identical unless noted.

• Right rear roller bracket is shown.

(1) Attach lifting device to rear roller bracket (1).

1
TM 9-2320-364-20-5

 21-153

NOTE

Note quantity of shims prior to

removal.

(2) Remove six screws (2), locknuts (3) and

shim(s) (4) from rear roller bracket (1) and

left rear roller bracket (5). Discard locknuts.

NOTE

Perform Step (3) for right side of

truck only.

(3) Remove locknut (6), two washers (7) and

screw (8) from rear roller bracket (1).

Discard locknut.

(4) With the aid of an assistant, remove five

screws (9) and locknuts (10) from rear 

roller bracket (1) frame (11) and rear

crossmember (12). Discard locknuts.

(5) With the aid of an assistant, remove five

screws (13) and locknuts (14) from rear

roller bracket (1) and frame (11).

(6) With the aid of an assistant, remove rear

roller bracket (1) from truck.

(7) Remove lifting device from rear roller

bracket (1).

1

5

10 9

11

12

LIFTING 

DEVICE

6

8

13

14

4

4

5

3

2

1

7

7
TM 9-2320-364-20-5

21-154

21-32. CONTAINER HANDLING UNIT (CHU) REAR BRACKET ASSEMBLY 

REPLACEMENT (CONT).

(8) Remove two screws (15), locknuts (16) and

light mounting plate (17) from rear roller

bracket (1). Discard locknuts.

(9) Remove screw (18), washer (19) and wire

rope (20) from rear roller bracket (1).

(10) Remove screw (21), washer (22) and wire

rope (20) from rear roller bracket (1).

NOTE

Perform Step (11) if wire rope is

damaged.

(11) Remove swaging sleeve (23) from wire

rope (20).

(12) Remove two screws (24), locknuts (25) and

stow plate (26) from rear roller bracket (1).

Discard locknuts.

15

16

17

19 18

20

23

24

25 26

1

22

21
TM 9-2320-364-20-5

 21-155

b. Installation.

NOTE

• Right rear roller bracket and

left rear roller bracket are

identical unless noted.

• Right rear roller bracket is

shown.

(1) Position stow plate (26), two screws (24) and

locknuts (25) to rear roller bracket (1). Do

not tighten screws.

NOTE

Perform Step (2) if wire rope was

removed.

(2) Install swaging sleeve (23) to wire rope (20).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(3) Apply sealing compound to threads of screw

(18) and screw (21).

(4) Install screw (21), washer (22) and loop end

of wire rope (20) on rear roller bracket (1).

Do not tighten screw.

(5) Position screw (18), washer (19) and end of

wire rope (20) on rear roller bracket (1).

NOTE

Wire must be pulled tight against

roller bracket when installed.

(6) Wrap wire (20) around screw (18) and under

washer (19) and tighten screws (18) and

(21).

(7) Install light mounting plate (17), two screws

(15) and locknuts (16) to rear roller bracket

(1).

20 19 18

15

16

17

19 18

20

23

24

25 26

1

22

21
TM 9-2320-364-20-5

21-156

21-32. CONTAINER HANDLING UNIT (CHU) REAR BRACKET ASSEMBLY 

REPLACEMENT (CONT).

Rear roller bracket weighs 150

lbs (68 kg). When removing one

rear roller bracket, ensure

remaining rear roller bracket is

supported. Attach suitable lifting

device to prevent possible injury

to personnel.

(8) Attach lifting device to rear roller bracket

(1). 

(9) With the aid of an assistant, position rear

roller bracket (1) on frame (11) and secure

with five screws (13) and locknuts (14). Do

not tighten screws.

(10) Position bottom two screws (2) and

locknuts (3) at center split of right rear

roller bracket (1) and left rear roller bracket

(5) to maintain alignment.

NOTE

Install shims as noted during

removal.

(11) Position shim(s) (4), if required, in center

split and install remaining four screws (2)

and locknuts (3).

(12) With the aid of an assistant, position five

screws (9) and locknuts (10) on rear roller

bracket (1) truck frame (11) and rear

crossmember (12).

NOTE

Perform Step (13) for right side

only.

(13) Install screw (8), two washers (7) and

locknut (6) on rear roller bracket (1).

(14) Tighten six locknuts (3) on screws (2).

(15) Tighten ten locknuts (14) and (10) on

screws (2) and (9).

(16) Remove lifting device from rear roller

bracket (1).

5

3

2

1

1

5

10 9

11

12

LIFTING 

DEVICE

6

8

13

14

4

7

7
TM 9-2320-364-20-5

 21-157

(17) Install slider arm, (Para 21-31).

(18) Install slider, (Para 21-29).

c. Adjustment.

NOTE

Both stow plates and wire ropes

are adjusted the same way. Right

side shown.

(1) Remove quick release pin (1) and pin (2)

from short strut (3).

NOTE

• Stow plate should be

positioned in center of short

strut.

• Ensure slider arm is fully

stowed and slider arm handle

contacts long strut prior to

tightening screws.

(2) Position short strut (3) on stow plate (4) in

stowed position and that handle of arm

assembly (5) contacts long strut (6).

(3) Tighten two screws (7) and locknuts (8) on

stow plate (4).

(4) Ensure wire rope (9) is tight.

d. Follow-on Maintenance:

• Install angled roller, (Para 15-16)

• Install horizontal roller, (Para 15-15)

• Install rear splash guard, (Para 17-39)

• Install light bar and brackets, (Para 21-27)

• Install hard lift strut, (Para 15-8)

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

SLIDERS SHOWN

REMOVED FOR

CLARITY 5

6

1 2

3

4 8

7 9
TM 9-2320-364-20-5

21-158

21-33. CONTAINER HANDLING UNIT (CHU) LONG STRUT BRACKET ASSEMBLY 

REPAIR.

This task covers:

a. Removal d. Assembly f. Adjustment

b. Disassembly e. Installation g. Follow-On Maintenance

c. Cleaning/Inspection

INITIAL SETUP

Materials/Parts

Antiseize Compound (Item 21, Appendix C)

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Slider arm in container mode,

(TM 9-2320-364-10)

Hardlift strut removed, (Para 15-6)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective 

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

Pliers, Retaining Ring (Item 49, Appendix G)

Puller Kit, Universal (Item 51, Appendix G)

Personnel Required

Two

Materials/Parts - Continued

Sealing Compound (Item 82, Appendix C)

Locknut (4) (Item 92, Appendix F)

Locknut (4) (Item 93, Appendix F)

a. Removal.

NOTE

There are two long strut bracket

assemblies. Both are removed the

same way. Right side is shown.

(1) Remove quick release pin (1) and pin (2)

from short strut (3) and long strut (4).

(2) Position flip lock (5) up to hold arm

assembly (6) out.

1

2 3

6

5

4
TM 9-2320-364-20-5

 21-159

Right strut bracket assembly

weighs 80 lbs (36 kg). Attach

suitable lifting device to prevent

possible injury to personnel.

(3) Remove two screws (7) and locknuts (8)

from strut bracket (9) and crossover tube

(10). Discard locknuts.

(4) Remove two screws (11) and locknuts (12) 

from strut bracket (9), hardlift bracket (13)

and frame (14). Discard locknuts.

(5) Remove two screws (15), locknuts (16) 

and strut bracket (9) from deck bracket (17)

and frame (14). Discard locknuts.

b. Disassembly.

Use care when removing snap

and retaining rings. Snap and

retaining rings are under spring

tension and can act as projectiles

when released and could cause

severe eye injury.

(1) Remove retaining ring (1), spacer (2) and pin

(3) from long strut (4). Discard retaining

ring.

(2) Remove long strut (4) from strut 

bracket (5).

9

7

8

10

11

12

13

14

3

2

1

4

5

15

16

17
TM 9-2320-364-20-5

21-160

21-33. CONTAINER HANDLING UNIT (CHU) LONG STRUT BRACKET ASSEMBLY 

REPAIR (CONT).

(3) Remove grease fitting (6) from end of 

long strut (4).

Use care when removing snap

and retaining rings. Snap and

retaining rings are under spring

tension and can act as projectiles

when released and could cause

severe eye injury.

(4) Remove retaining ring (7), spacer (8) and

bearing (9) from long strut (4).

(5) Remove wire rope (10), quick release pin

(11), and pin (12) from cushion clip (13).

NOTE

Perform Step (6) if wire rope is

damaged.

(6) Remove two swaging sleeves (14) from wire

rope (10). 

NOTE

• Perform Steps (7) and (8) if

pin end is damaged.

• Screw is used to secure pin

end to long strut.

• Note position of pin end prior

to removal.

(7) Remove screw (15) and cushion clip (13)

from long strut (4).

(8) Remove pin end (16) from end of long strut

(4).

10

16

11

12

4

15

13

6

7

8

9

14

14
TM 9-2320-364-20-5

 21-161

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

(1) Clean all metal parts with drycleaning solvent.

Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.) or

injury to personnel may result.

(2) Dry parts with compressed air.

(3) Inspect parts for breaks, cracks, burrs and sharp edges. Look for unusual signs of wear on strut.

(4) Replace all damaged parts.
TM 9-2320-364-20-5

21-162

21-33. CONTAINER HANDLING UNIT (CHU) LONG STRUT BRACKET ASSEMBLY 

REPAIR (CONT).

d. Assembly.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

NOTE

• Perform Steps (1) through (4)

if pin end was removed.

• If strut bracket and/or long

strut are being replaced,

perform f. Adjustment.

• Position pin end in long strut

as noted during disassembly.

(1) Apply antiseize compound to threads of pin

end (16).

(2) Position pin end (16) in end of long strut (4).

(3) Position cushion clip (13) on pin (12), lock

pin (11), wire rope (10) and swaging sleeves

(14).

(4) Position cushion clip (13) and screw (15) on

long strut (4).

10

16

11

12

4

15

13

14

14
TM 9-2320-364-20-5

 21-163

(5) Apply antiseize compound to outer 

surface of bearing (9).

Use care when installing snap and

retaining rings. Snap and

retaining rings are under spring

tension and can act as projectiles

when released and could cause

severe eye injury.

(6) Install bearing (9), spacer (8) and retaining

ring (7) in bore of long strut (4).

(7) Install grease fitting (6) in long strut (4).

NOTE

Beveled edge of spacer faces

bearing in long strut.

(8) Install long strut (4) in strut bracket (5) with

pin (3), spacer (2) and retaining ring (1).

4

6

7

8

9

3

2

1

4

5
TM 9-2320-364-20-5

21-164

21-33. CONTAINER HANDLING UNIT (CHU) LONG STRUT BRACKET ASSEMBLY 

REPAIR (CONT).

e. Installation.

Right strut bracket assembly

weighs 80 lbs (36 kg). Attach

suitable lifting device to prevent

possible injury to personnel.

NOTE

There are two long strut bracket

assemblies. Both are installed the

same way. Right side is shown.

(1) Install two screws (15), locknuts (16) and

strut bracket (9) on deck bracket (17) and

frame (14).

(2) Install two screws (11) and locknuts (12) on

strut bracket (9), hardlift bracket (13) and

frame (14).

(3) Install two screws (7) and locknuts (8) on

strut bracket (9) and crossover tube (10).

(4) Rotate arm assembly (6) with handle and

disengage flip lock (5).

(5) Attach long strut (4) and short strut (3) with

pin (2) and quick release pin (1).

1

2 3 4

6

5

9

7

8

10

11

12

13

14

15

16

17
TM 9-2320-364-20-5

 21-165

f. Adjustment.

(1) Deploy both slider assemblies by extending short and long struts (TM 9-2320-364-10).

(2) With the aid of an assistant, measure distance between center of slider pivot pins (1).

NOTE

• Adjustment of struts is performed in Steps (4) through (13).

• If distance measured is 88.62 in. to 89 in. (225.09 cm to 226.06 cm), no adjustment is

required.

(3) Adjust long struts (2) so distance measured is 88.62 in. to 89 in. (225.09 cm to 226.06 cm) between slider

pivot pin (1) centers.

2

1 1

88.62 IN. to 89.0 IN.

(225.09 CM to 226.06 CM)
TM 9-2320-364-20-5

21-166

21-33. CONTAINER HANDLING UNIT (CHU) LONG STRUT BRACKET ASSEMBLY 

REPAIR (CONT).

(4) Remove quick release pin (3) and pin (4) from short strut (5) and long strut (2).

(5) Using handle of arm assembly (6), rotate arm assembly out to separate short strut (5) and long strut (2).

(6) Position flip lock (7) up to hold arm assembly (6) out. Release arm assembly.

NOTE

• Rotating pin end of long strut counterclockwise 1/2 turn will decrease width measurement

by approximately 1/16 in. (1.59 mm).

• Rotating pin end of long strut clockwise 1/2 turn will increase width measurement by

approximately 1/16 in. (1.59 mm).

• Adjust both RH and LH long struts equally to obtain the correct width measurement.

(7) Remove screw (8) and cushion clip (9) from long strut (2).

Do not unscrew pin end too far. Gap between long strut tube and pin end flange should not

exceed 0.75 inches (19 mm). Failure to have sufficient engagement of pin end into long strut

could result in damage to equipment.

(8) Rotate pin end (10) as required for correct width measurement.

5

2

3

4

9

8

10

2

6

7
TM 9-2320-364-20-5

 21-167

Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors,

and are harmful to skin and clothing. To avoid injury or death, keep away from open fire and

use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or

clothing, wash immediately with soap and water.

NOTE

Ensure hole in pin end align with hole for cushion clip.

(9) Apply sealing compound (loctite 242) to threads of screw (8).

(10) Install screw (8) and cushion clip (9) to long strut (2).

(11) Align long strut (2) with short strut (5).

(12) Using handle of arm assembly (6), rotate arm assembly and disengage flip lock (7).

(13) Position long strut (2) in short strut (5) and install pin (4) and quick release pin (3).

(14) Repeat Steps (4) through (13) for left side.

(15) Repeat Steps (2) through (14) as necessary.

g. Follow-On Maintenance:

• Install hardlift strut, (Para 15-6).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

5

2

3

4

9

8

2

6

7
TM 9-2320-364-20-5

21-168

This task covers:

a. Removal d. Assembly f. Adjustment

b. Disassembly e. Installation g. Follow-On Maintenance

c. Cleaning/Inspection

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Rail transport corner ISO locks removed, 

(TM 9-2320-364-10)

Lifting frame on ground, (TM 9-2320-364-10)

Container guides removed, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

Lifting Device, Minimum Capacity

400 lbs (181 kg)

21-34. CONTAINER HANDLING UNIT (CHU) STOW WELDMENT REPLACEMENT.

Materials/Parts

Locknuts (12) (Item 91, Appendix F)

Locknuts (4) (Item 92, Appendix F)

Personnel Required

Two

a. Removal.

Stow weldment weighs 410 lbs

(186 kg). Attach suitable lifting

device to prevent possible injury

to personnel.

(1) Attach lifting device to stow weldment (1).

(2) Support stow weldment (1) and remove two

screws (2) and locknuts (3) 

from top of stow weldment support 

brace (4). Discard locknuts.

(3) Remove two screws (5) and locknuts (6)

from bottom of stow weldment support 

brace (4) and crossmember assembly (7).

Discard locknuts.

(4) Remove stow weldment support brace (4)

from stow weldment (1).

2

4

5

7

3

6

1
TM 9-2320-364-20-5

 21-169

(5) Remove four screws (8) and locknuts (9)

from stow weldment (1) and front support

assembly (10). Discard locknuts.

(6) With the aid of an assistant, remove stow

weldment (1) from front support assembly

(10).

(7) Position stow weldment (1) on clean work

surface and remove lifting device.

b. Disassembly.

(1) Remove four snap pins (1), pins (2) and two

rail transport struts (3) from stow weldment

(4).

NOTE

Perform Step (2) if wire ropes are

damaged.

(2) Remove four swaging sleeves (5) from two

wire ropes (6),

(3) Remove eight screws (7), locknuts (8) and

lifting frame stow hooks (9) from stow

weldment (4). Discard locknuts.

NOTE

Perform Step (4) if tether pin is

damaged.

(4) Remove four swaging sleeves (10) and two

wire ropes (11) from tether pins (12) and

quick release pins (13) from bottom of stow

weldment (4).

4

5

6

1

2

3

7

8

9

12

5

5

6

5

1

1

8

9

10

10

11

13

2

10
TM 9-2320-364-20-5

21-170

21-34. CONTAINER HANDLING UNIT (CHU) STOW WELDMENT 

REPLACEMENT (CONT).

c. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

(1) Clean all metal parts with drycleaning solvent.

Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.) or

injury to personnel may result.

(2) Dry parts with compressed air.

(3) Inspect parts for breaks, cracks, burrs and sharp edges. Look for unusual signs of wear on stow weldment

frame.

(4) Replace all damaged parts.
TM 9-2320-364-20-5

 21-171

d. Assembly.

NOTE

• Perform Step (1) if tether pin

was removed.

• Wire rope is positioned

through hole in bottom of

stow weldment.

(1) Attach two tether pins (12) and quick 

release pins (13) to bottom of stow

weldment (4) with two wire ropes (11) 

and four swaging sleeves (10).

(2) Position two lifting frame stow hooks (9) 

on stow weldment (4) with eight screws (7)

and locknuts (8). Do not tighten.

NOTE

Perform Step (3) if wire ropes

were removed.

(3) Attach two wire ropes (6) with four swaging

sleeves (5) to pins (2) and snap pins (1).

(4) Install two rail transport struts (3) on stow

weldment (4) with four pins (2) and snap

pins (1).

4

5

6

1

2

3

7

8

9

12

5

5

6

5

1

10

11

13

2

10
TM 9-2320-364-20-5

21-172

21-34. CONTAINER HANDLING UNIT (CHU) STOW WELDMENT 

REPLACEMENT (CONT).

e. Installation.

Stow weldment weighs 410 lbs

(186.14 kg). Attach suitable

lifting device to prevent possible

injury to personnel.

(1) Attach suitable lifting device to stow

weldment (1).

(2) With the aid of an assistant, position stow

weldment (1) on front support assembly

(10).

(3) Install four screws (8) and locknuts (9) on

stow weldment (1) and front support

assembly (10).

(4) With the aid of an assistant, position stow

weldment support brace (4) on stow

weldment (1).

(5) Install bottom of stow weldment support

brace (4) with two screws (5) and locknuts

(6) on crossmember assembly (7).

(6) Install top of stow weldment support brace

(4) with two screws (2) and locknuts (3) on

stow weldment (1).

2

4

5

7

3

6

1

1

8

9

10
TM 9-2320-364-20-5

 21-173

f. Adjustment.

(1) Position lifting frame (1) in stow mode 

(TM 9-2320-364-10).

(2) Start engine (TM 9-2320-364-10).

Engine speed must be at idle

before using hydraulic selector

switch, or damage to equipment

may result.

(3) Set hydraulic selector switch (2) to AUTO

and stow LHS (TM 9-2320-364-10).

(4) Extend LHS (3) to lifting frame (1).

(5) Position lifting frame (1) on truck with LHS

in stow mode (TM 9-2320-364-10).

NOTE

Lifting frame is properly stowed

when completely seated on cone

weldment.

(6) Ensure lifting frame (1) is completely seated

on cone weldment (4).

NOTE

Perform Steps (7) and (8), as

necessary, if lifting frame is not

completely seated.

(7) Raise lifting frame (1) with LHS (3)

approximately 12 in. (30 cm) then lower

lifting frame on cone weldment (4).

(8) Repeat Step (6).

(9) Shut OFF engine.

NOTE

Ensure lifting frame wear pads

contact LHS hook arm.

(10) With the aid of an assistant, position lifting

frame (1) towards rear of truck until lifting

frame wear pads (5) contact LHS.

2

1

3 STEERING WHEEL

SHOWN REMOVED

FOR CLARITY

3

1

4

5
TM 9-2320-364-20-5

21-174

21-34. CONTAINER HANDLING UNIT (CHU) STOW WELDMENT 

REPLACEMENT (CONT).

NOTE

• Stow hooks are not tightened

on stow weldment.

• Stow hook should have an

even gap around lifting frame

pin.

(11) Tighten six screws (6) and locknuts (7) on

two hooks (8) and stow weldment (9).

(12) Verify lifting frame wear pad gap to LHS

hook arm is less than 1/8 in. (3.2 mm). If

not repeat Steps (6) through (11).

g. Follow-On Maintenance:

• Install rail transport corner ISO locks, (TM 9-2320-364-10).

• Install container guides, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

6 8

7

9
TM 9-2320-364-20-5

 21-175

21-35. CONTAINER HANDLING UNIT (CHU) LIFTING FRAME ASSEMBLY 

REPLACEMENT.

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP Equipment Condition

Lifting frame in 82 in. (208 cm) mode, 

(TM 9-9-2320-364-10)

Lifting frame removed from truck,

(TM 9-2320-364-10)

Locking plate removed, (Para 21-36)

Lower container lock plate removed, (Para 21-37)

Flipper bracket and lock plate removed, 

(Para 21-38)

Lifting frame strap removed, (Para 21-47)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Materials/Parts

Sealing Compound (Item 83, Appendix C)

Personnel Required

Two

a. Removal.

NOTE

• There are two slide arms. Both are removed the same way. Right side is shown.

• Only remove wire ropes, swaging sleeves, pins and lock pins if components are damaged.

(1) Remove pin (1), lock pin (2) and upper hook (3) from slide arm (4).

(2) Remove two swaging sleeves (5) and wire rope (6) from pin (1) and lock pin (2).

1

2

3

4

5

6

5
TM 9-2320-364-20-5

21-176

21-35. CONTAINER HANDLING UNIT (CHU) LIFTING FRAME ASSEMBLY 

REPLACEMENT (CONT).

(3) Remove lock pin (7) and pin (8) from lifting

frame stow bracket (9).

(4) Remove two swaging sleeves (10) and wire

rope (11) from pin (8) and lock pin (7).

(5) Remove lock pin (12), collar (13), pin (14)

and lifting hook (15) from slide arm (4).

(6) Remove two swaging sleeves (16) and wire

rope (17) from pin (14) and lock pin (12).

Slide arm weighs 65 lbs (29 kg).

Attach suitable lifting device to

prevent possible injury to

personnel.

(7) Attach lifting device to slide arm (4).

(8) With the aid of an assistant, remove slide

arm (4) from lifting frame (18).

(9) Remove lifting device from slide arm (4).

9

17

7

8

10

11

12 13

14

4 16

15

16

18

10
TM 9-2320-364-20-5

 21-177

NOTE

There are two six foot hooks.

Both are removed the same way.

Right side is shown.

(10) Remove lock pin (19), pin (20) and six foot

hook (21) from lifting frame stow bracket

(22).

(11) Remove two swaging sleeves (23) and wire

rope (24) from six foot hook (21), pin (20)

and lock pin (19).

(12) Remove lock pin (25), pin (26) and bail 

bar lock (27) from lifting frame stow

bracket (28).

(13) Remove two swaging sleeves (29), wire

rope (30) from bail bar lock (27), pin (26)

and lock pin (25).

(14) Remove lock pin (31) from lifting frame

stow bracket (32).

(15) Remove two swaging sleeves (33) and wire

rope (34) from lifting frame stow bracket

(32) and lock pin (31).

30

29

28

31

27

34

33

32

26

25

29

33

24

23

22

21

20

19

23
TM 9-2320-364-20-5

21-178

21-35. CONTAINER HANDLING UNIT (CHU) LIFTING FRAME ASSEMBLY 

REPLACEMENT (CONT).

NOTE

There are two container locks and

half height container hooks. Both

are removed the same way. Right

side is shown.

(16) Remove lock pin (35), pin (36) and

container lock (37) from lifting frame

stow bracket (38).

(17) Remove two swaging sleeves (39) and wire

rope (40) from container lock (37), pin (36)

and lock pin (35).

(18) Remove lock pin (41), pin (42) and half

height container hook (43) from lifting

frame stow bracket (38).

(19) Remove two swaging sleeves (44) and wire

rope (45) from half height container hook

(43), pin (42) and lock pin (41).

(20) Remove four screws (46) and two long

wear pads (47) from lifting frame (18).

(21) Remove four screws (48) and two short

wear pads (49) from lifting frame (18).

46

45 44

43

42

41

40

39

18

38

37

36

35

49 48

47

44

39
TM 9-2320-364-20-5

 21-179

Lifting frame weighs 1600 lbs

(726 kg). Attach suitable lifting

device to prevent possible injury

to personnel.

(22) Attach lifting device to lifting frame (18).

(23) With the aid of an assistant, lift and support

lifting frame (18).

(24) Support lower half of support leg (50) and

remove lock pin (51) and pin (52).

(25) Remove lower half of support leg (50) from

upper half of support leg (53).

(26) With the aid of an assistant, support upper

half of support leg (53) and remove two

lock pins (54) from upper half of support

leg and lifting frame (18).

(27) Remove upper half of support leg (53) from

lifting frame (18).

(28) Lower lifting frame (18) to ground and

remove lifting device.

(29) Remove two swaging sleeves (55) and wire

rope (56) from lockpin (51), pin (52) and

upper half of support leg (53).

(30) Remove four swaging sleeves (57) and two

wire ropes (58) from two lock pins (54) and

upper half of support leg (53).

53

52

51 50

54 54

18

18

58

57

55

54

52 56 53

51

55

54

57

57

57 58
TM 9-2320-364-20-5

21-180

21-35. CONTAINER HANDLING UNIT (CHU) LIFTING FRAME ASSEMBLY 

REPLACEMENT (CONT).

b. Installation.

NOTE

Install wire ropes, swaging

sleeves, pins and lock pins, only

if removed.

(1) Install two lock pins (54) with wire ropes

(58) and four swaging sleeves (57) on upper

half of support leg (53).

(2) Install pin (52), lockpin (51) with wire rope

(56) and two swaging sleeves (55) on upper

half of suport leg (53).

Lifting frame weighs 1600 lbs

(726 kg). Attach suitable lifting

device to prevent possible injury

to personnel.

(3) Attach lifting device to lifting frame (18).

(4) With the aid of an assistant, lift and support

lifting frame (18).

(5) With the aid of an assistant, install upper half

of support leg (53) on lifting frame (18) with

two lock pins (54).

(6) Install lower half of support leg (50) on

upper half of support leg (53) with pin (52)

and lockpin (51).

58

57

55

54

52 56 53

51

55

54

57

57

57 58

53

52

51 50

54 54

18
TM 9-2320-364-20-5

 21-181

(7) With lifting device, position lifting frame

(18) on ground.

(8) Remove lifting device from lifting frame

(18).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(9) Apply sealing compound to threads of four

screws (46) and (48).

(10) Install two short wear pads (49) to lifting

frame (18) with four screws (48).

(11) Install two long wear pads (47) to lifting

frame (18) with four screws (46).

18

46

18

49 48

47
TM 9-2320-364-20-5

21-182

21-35. CONTAINER HANDLING UNIT (CHU) LIFTING FRAME ASSEMBLY 

REPLACEMENT (CONT).

NOTE

There are two container locks and

half height container hooks. Both

are installed the same way. Right

side is shown.

(12) Install pin (42) and lock pin (41) with wire

rope (45) and swaging sleeves (44) on half

height container hook (43).

(13) Install half height container hook (43) on

lifting frame stow bracket (38) with pin (42)

and lock pin (41).

(14) Install pin (36) and lock pin (35) with wire

rope (40) and swaging sleeves (39) on

container lock (37).

(15) Install container lock (37) on lifting frame

stow bracket (38) with pin (36) and lock pin

(35).

45 44

43

42

41

40

39

38

37

36

35

44

39
TM 9-2320-364-20-5

 21-183

(16) Install lock pin (31) with wire rope (34) and

swaging sleeves (33) on lifting frame stow

bracket (28).

(17) Install pin (26) and lock pin (25) with wire

rope (30) and swaging sleeves (29) on bail

bar lock (27).

(18) Install bail bar lock (27) on lifting 

frame stow bracket (28) with pin (26) and

lock pin (25).

NOTE

There are two six foot hooks.

Both are installed the same way.

Right side is shown.

(19) Install pin (20) and lock pin (19) with wire

rope (24) and swaging sleeves (23) on six

foot hook (21).

(20) Install six foot hook (21) on lifting frame

stow bracket (22) with pin (20) and lock pin

(19).

24

23

22

21

20

19

23

30

29

28

31

27

34

33

32

26

25

29

33
TM 9-2320-364-20-5

21-184

21-35. CONTAINER HANDLING UNIT (CHU) LIFTING FRAME ASSEMBLY 

REPLACEMENT (CONT).

Slide arm weighs 65 lbs (29 kg).

Attach suitable lifting device to

prevent possible injury to

personnel.

(21) Attach lifting device to slide arm (4).

(22) With the aid of an assistant, position slide

arm (4) on lifting frame (18).

(23) Install wire rope (17) and swaging sleeves

(16) on pin (14) and lockpin (12).

(24) Install lifting hook (15) on slide arm (4)

with pin (14), collar (13) and lock pin (12).

(25) Install pin (8) and lock pin (7) with wire

rope (11) and two swaging sleeves (10) on

lifting frame stow bracket (9)

17

12 13

14

4 16

15

16

18

9

7

8

10

11 10
TM 9-2320-364-20-5

 21-185

(26) Install pin (1) and lock pin (2) with wire

rope (6) and two swaging sleeves (5) on

upper hook (3).

(27) Install upper hook (3) on slide arm (4) with

pin (1) and lock pin (2).

c. Follow-on Maintenance:

• Install lifting frame strap, (Para 21-47).

• Install flipper bracket and lock plate, (Para 21-38).

• Install lower container lock plate, (Para 21-37).

• Install locking plate, (Para 21-36).

• Lubricate lifting frame, (TM 9-2320-364-10).

• Install lifting frame on truck, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

1

2

3

4

5

6

5
TM 9-2320-364-20-5

21-186

21-36. CONTAINER HANDLING UNIT (CHU) LIFTING FRAME LOCKING PLATE 

ASSEMBLY REPLACEMENT.

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Materials/Parts

Pin, Cotter (2) (Item 267, Appendix F)

Equipment Condition

Lifting frame removed from truck, 

(TM 9-2320-364-10)

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

a. Removal.

NOTE

There are two locking plate

assemblies. Both are installed the

same way. Left side is shown.

(1) Remove quick release pin (1) from lifting

frame (2).

(2) Remove two cotter pins (3), hinge pin (4)

and locking plate (5) from lifting frame (2).

Discard cotter pins.

NOTE

Perform Step (3) if wire rope or

pins are damaged.

(3) Remove two swaging sleeves (6), wire rope

(7) and quick release pin (1) from locking

plate (5).

6

7 1

5

3

4

2

3

6
TM 9-2320-364-20-5

 21-187

b. Disassembly.

NOTE

• There are two locking plate

assemblies. Both are

installed the same way. Left

side is shown.

• Perform Step (1) if wire rope

or pins were removed.

(1) Install wire rope (7) to quick release pin (1)

and locking plate (5) with two swaging

sleeves (6).

(2) Install locking plate (5) on lifting frame (2)

with hinge pin (4) and two cotter pins (3) .

(3) Install quick release pin (1) on lifting frame

(2).

c. Follow-On Maintenance:

• Lubricate locking plate, (TM 9-2320-364-10).

• Install lifting frame on truck, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

6

7 1

5

3

4

2

3

6
TM 9-2320-364-20-5

21-188

21-37. CONTAINER HANDLING UNIT (CHU) LIFTING FRAME LOWER CONTAINER 

LOCK PLATE REPAIR.

This task covers:

a. Removal c. Installation

b. Cleaning/Inspection d. Follow-On Maintenance

INITIAL SETUP

Materials/Parts

Sealing Compound (Item 83, Appendix C)

Equipment Condition

Lifting frame removed from truck, 

(TM 9-2320-364-10)

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective 

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

a. Removal.

NOTE

There are two lower container

lock plates. Both are removed the

same way. Right side is shown.

(1) Raise handle lock plate (1) and rotate lower

container lock handle (2) towards center of

lifting frame (3) to unlock.

NOTE

Ensure tab on hand nut faces up.

(2) Release handle lock plate (1) on lifting frame

(3).

1

2

TAB

UNLOCKED

3

LOCKED
TM 9-2320-364-20-5

 21-189

(3) Remove two nuts (4) from screws (5).

NOTE

Note position of springs prior to

removal.

(4) Remove two screws (5), with springs (6) and

handle lock plate (1) from lifting frame (3).

(5) Remove springs (6) from screws (5).

b. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

(1) Clean all metal parts with drycleaning solvent.

Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.) or

injury to personnel may result.

(2) Dry parts with compressed air.

(3) Inspect parts for breaks, cracks, burrs and sharp edges. Look for unusual signs of wear on lockplate.

(4) Replace all damaged parts.

4

5

6

3

1
TM 9-2320-364-20-5

21-190

21-37. CONTAINER HANDLING UNIT (CHU) LIFTING FRAME LOWER CONTAINER 

LOCK PLATE REPAIR (CONT).

c. Installation.

NOTE

• There are two lower

container lock plates. Both

are installed the same way.

Right side is shown.

• Install springs as noted prior

to removal.

(1) Position springs (6) on screws (5).

NOTE

It will be necessary to compress

springs before installing screws.

(2) Install handle lock plate (1) on lifting frame

(3) with two screws (5) and springs (6).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(3) Apply sealing compound to threads of two

screws (5).

4

5

6

3

1
TM 9-2320-364-20-5

 21-191

(4) Install two nuts (4) on screws (5).

NOTE

Ensure tab on hand nut faces up.

(5) Hold handle lock plate (1) up and rotate

lower container lock handle (2) up to

(locked) position.

(6) Release handle lock plate (1) on lifting frame

(3).

d. Follow-On Maintenance:

• Lubricate lock plate, (TM 9-2320-364-10).

• Install lifting frame on truck, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

1

2

3

TAB LOCKED
TM 9-2320-364-20-5

21-192

21-38. CONTAINER HANDLING UNIT (CHU) LIFTING FRAME FLIPPER BRACKET 

AND LOCK PLATE REPAIR.

This task covers:

a. Removal c. Installation e. Follow-On Maintenance

b. Cleaning/Inspection d. Adjustment

INITIAL SETUP

Materials/Parts (cont)

Lockwasher (2) (Item 172, Appendix F)

Cotter pin (2) (Item 267, Appendix F)

Cotter pin (Item 268, Appendix F)

Spring pin (2) (Item 285, Appendix F)

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Remove lifting frame from truck, 

(TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Compressor Unit, Air (Item 11, Appendix G)

Gloves, Chemical Oil Protective 

(Item 28, Appendix G)

Goggles, Industrial (Item 30, Appendix G)

Gun, Air Blow (Item 31, Appendix G)

Materials/Parts

Antiseize Compound (Item 21, Appendix C)

Sealing, Compound (Item 83, Appendix C)

a. Removal.

Use care when removing springs.

Springs are under tension and can

act as projectiles when released

and could cause injury to

personnel.

NOTE

There are two flipper pin

brackets. Both are removed the

same way. Left side is shown.

(1) Remove cotter pin (1), flipper lock pin (2),

spring (3) and lock handle (4) from flipper

pin bracket (5) and lifting frame (6).

Discard cotter pin.

5

6

4

1

3

2
TM 9-2320-364-20-5

 21-193

(2) Remove two screws (7), lockwashers (8),

washers (9) and flipper pin bracket (5) from

lifting frame (6). Discard lockwashers.

NOTE

There are two flippers and flipper

locks. Both are removed the

same way. Left side is shown.

(3) Remove screw (10) and washer (11) from

pin (12).

(4) Remove screw (13) and washer (14) from

pin (15).

(5) Remove two spring pins (16) from flipper

bracket (17). Discard spring pins.

(6) Remove pin (12) from flipper bracket (17)

and boss (18).

(7) Remove pin (15) from boss (19) and flipper

bracket (17).

5

6

7

8

9

10

11

14

12

16 17 15

13

17

16

18

19
TM 9-2320-364-20-5

21-194

21-38. CONTAINER HANDLING UNIT (CHU) LIFTING FRAME FLIPPER BRACKET 

AND LOCK PLATE REPAIR (CONT).

(8) Remove flipper bracket (17) from boss (18)

and boss (19).

(9) Remove four bushings (20) from boss (18)

and boss (19).

Use care when removing springs.

Springs are under tension and can

act as projectiles when released

and could cause injury to

personnel.

(10) Remove spring (21) from flipper bracket

(17) and lock plate (22).

(11) Remove retaining ring (23), washer (24),

spring (25) and pin handle (26) from flipper

bracket (17).

(12) Remove two cotter pins (27), pivot pin (28)

and lock plate (22) from flipper bracket

(17). Discard cotter pins.

(13) Remove jam nut (29) and screw (30) from

flipper bracket (17).

20

23

18

17

22

24

25

26

28 29

30

17

19

20

27

21

27
TM 9-2320-364-20-5

 21-195

b. Cleaning/Inspection.

• Drycleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles, face

shield, and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using

solvent. The flashpoint for Type II Drycleaning Solvent is 140 degrees F (60 degrees C) and

Type III Drycleaning Solvent is 200 degrees F (93 degrees C). Failure to do so may result in

injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention.

(1) Clean all metal parts with drycleaning solvent.

Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with

effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.) or

injury to personnel may result.

(2) Dry parts with compressed air.

(3) Inspect parts for breaks, cracks, burrs and sharp edges.

(4) Replace all damaged parts.
TM 9-2320-364-20-5

21-196

21-38. CONTAINER HANDLING UNIT (CHU) LIFTING FRAME FLIPPER BRACKET 

AND LOCK PLATE REPAIR (CONT).

c. Installation.

NOTE

There are two flippers and flipper

locks. Both are removed the

same way. Left side is shown.

(1) Install screw (30) and jam nut (29) on flipper

bracket (17). Do not tighten jam nut.

(2) Install lock plate (22) with pivot pin (28) and

two cotter pins (27) on flipper bracket (17).

Use care when removing springs.

Springs are under tension and can

act as projectiles when released

and could cause injury to

personnel.

(3) Install pin handle (26), spring (25), washer

(24) and retaining ring (23) on flipper

bracket (17).

(4) Install spring (21) on lock plate (22) and

flipper bracket (17).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(5) Apply light coat of sealing compound to four

bushings (20).

(6) Install four bushings (20) in boss (19) and

boss (18).

(7) Position flipper bracket (17) on boss (19)

and boss (18).

23

22

24

25

26

28 29

30

17

27

21

27

20

18

17

19

20
TM 9-2320-364-20-5

 21-197

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(8) Apply antiseize on pin (15).

(9) Align pin hole in pin (15) with pin hole in

lower part of flipper bracket (17) and install

pin in flipper bracket and boss (19).

(10) Apply antiseize on pin (12).

(11) Align pin hole in pin (12) with pin hole in

upper part of flipper bracket (17) and install

pin into flipper bracket and boss (18).

(12) Install two spring pins (16) into flipper

bracket (17), pin (12) and pin (15).

(13) Position washer (14) and screw (13) in end

of pin (15). Do not tighten screw.

(14) Position washer (11) and screw (10) in end

of pin (12). Do not tighten screw.

10

11

14

12

16 17 15

13

17

16

18

19
TM 9-2320-364-20-5

21-198

21-38. CONTAINER HANDLING UNIT (CHU) LIFTING FRAME FLIPPER BRACKET 

AND LOCK PLATE REPAIR (CONT).

NOTE

There are two flipper pin

brackets. Both are installed the

same way. Left side is shown.

(15) Install flipper pin bracket (5), two washers

(9), lockwashers (8) and screws (7) on

lifting frame (6).

Use care when installing springs.

Springs are under tension and can

act as projectiles when released

and could cause injury to

personnel.

(16) Position lock handle (4) through welded

support on lifting frame (6), through flipper

pin bracket (5) and install using spring (3),

flipper lock pin (2) and cotter pin (1).

5

6

7

8

9

6

5

6

4

1

3

2
TM 9-2320-364-20-5

 21-199

d. Adjustment.

(1) Remove screw (1) and washer (2) in boss (3)

of flipper bracket (4).

(2) Remove screw (5) and washer (6) in boss (7)

of flipper bracket (4).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(3) Apply sealing compound to threads of screw

(5).

(4) Position washer (6) and screw (5) on pin (8)

and boss (7) of flipper bracket (4).

(5) Tighten screw (5) until washer (6) is tight

against boss (7) of flipper bracket (4).

(6) Loosen screw (5) approximately 1/4 turn

until washer (6) moves freely.

(7) Apply sealing compound to threads of screw

(1).

(8) Position washer (2) and screw (1) on pin (9)

and boss (3) of flipper bracket (4).

(9) Tighten screw (1) until washer (2) is tight against boss (3) of flipper bracket (4).

(10) Loosen screw (1) approximately 1/4 turn until washer (2) moves freely.

(11) Ensure washer (6) on boss (7) moves freely.

NOTE

Let sealing compound cure, approximately 15 minutes before operating flipper bracket.

(12) Rotate flipper bracket (4) and ensure screws (1) and (5) rotate flipper bracket, and washers (2) and (6)

move freely.

2

1

3

4

5

6

7

8

9
TM 9-2320-364-20-5

21-200

21-38. CONTAINER HANDLING UNIT (CHU) LIFTING FRAME FLIPPER BRACKET 

AND LOCK PLATE REPAIR (CONT).

(13) Loosen jam nut (10) on screw (11).

(14) Adjust screw (11) to contact plate (12) on

wear pad (13) when flipper lock pin (14) is

aligned with hole in end of flipper bracket

(15).

(15) Tighten jam nut (10) to flipper bracket (15).

e. Follow-On Maintenance:

• Lubricate flipper bracket, (TM 9-2320-364-10).

• Install lifting frame on truck, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

10

11

13

14

15 HOLE

12
TM 9-2320-364-20-5

 21-201

21-39. SELF-RECOVERY WINCH (SRW) CONTAINER HANDLING UNIT (CHU) REAR 

GUIDE REPLACEMENT.

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Lifting Device, Minimum Capacity

70 lbs (32 kg)

Materials/Parts

Sealing Compound (Item 82, Appendix C)

Locknut (4) (Item 92, Appendix F)

Personnel Required

Two

Materials/Parts (cont)

Locknut (Item 100, Appendix F)

Lockwasher (2) (Item 166, Appendix F)

a. Removal.

Rear guide assembly weighs 70

lbs (32 kg). Attach suitable

lifting device to prevent possible

injury to personnel.

(1) Attach lifting device to rear guide (1).

(2) With the aid of an assistant, remove four

locknuts (2) and screws (3) from rear guide

(1). Discard locknuts.

(3) With the aid of an assistant, remove locknut

(4), washer (5) and screw (6) from rear guide

(1). Discard locknut.

(4) With the aid of an assistant, remove two

screws (7), lockwashers (8) and rear guide

(1) from frame (9). Discard lockwashers.

(5) Position rear guide (1) on clean work surface

and remove lifting device.

(6) Remove screw (10) and axle stop (11) from

rear guide (1).

1

2

3

4

8

9

10

11

7

6

5

1
TM 9-2320-364-20-5

21-202

21-39. SELF-RECOVERY WINCH (SRW) CONTAINER HANDLING UNIT (CHU) REAR 

GUIDE REPLACEMENT (CONT).

b. Installation.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(1) Apply sealing compound to threads of screw

(10).

(2) Install screw (10) and axle stop (11) on rear

guide (1).

Rear guide assembly weighs 70

lbs (32 kg). Attach suitable

lifting device to prevent possible

injury to personnel.

(3) Attach lifting device to rear guide (1).

(4) With the aid of an assistant, position rear

guide (1) on frame (9) with two lockwashers

(8) and screws (7).

(5) Install screw (6), washer (5) and locknut (4)

on rear guide (1).

(6) With the aid of an assistant, position four

locknuts (2) and screws (3) on rear guide (1).

(7) With the aid of an assistant, tighten two

screws (7) on rear guide (1).

(8) With the aid of an assistant, tighten four

locknuts (2) on rear guide (1).

(9) Remove lifting device from rear guide (1).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

1

2

3

4

8

9

10

11

7

6

5

1
TM 9-2320-364-20-5

 21-203

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

21-40. CONTAINER HANDLING UNIT (CHU) DECK WELDMENT REPLACEMENT.

Materials/Parts

Lockwasher (4) (Item 168, Appendix F)

a. Removal.

NOTE

Left and right deck weldments are identical. Right deck weldment is shown.

(1) Remove two screws (1), lockwashers (2) and washers (3) from deck weldment (4) and front support

assembly (5). Discard lockwashers.

(2) Remove two screws (6), lockwashers (7) and six washers (8) from deck weldment (4). Discard

lockwashers.

(3) Remove deck weldment (4) from front support assembly (5).

1

6

2

3

5

8

5

7

8
TM 9-2320-364-20-5

21-204

21-40. CONTAINER HANDLING UNIT (CHU) DECK WELDMENT 

REPLACEMENT (CONT).

b. Installation.

NOTE

Left and right deck weldments are

identical. Right deck weldment is

shown.

(1) Position deck weldment (5) on front support

assembly (5).

(2) Install six washers (8), two lockwashers (7)

and screws (6) and deck weldment (5) on

front support assembly (5).

(3) Install two washers (3), lockwashers (2) and

screws (1) to deck weldment (5) and front

support assembly (5).

c. Follow-on Maintenance:

Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

1

6

2

3

5

8

5

7

8
TM 9-2320-364-20-5

 21-205

21-41. CONTAINER HANDLING UNIT (CHU) BUMPER WELDMENT SUPPORT 

REPLACEMENT.

This task covers:

a. Removal c. Adjustment

b. Installation d. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Lifting frame removed from truck, 

(TM 9-2320-364-10)

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Materials/Parts

Sealing Compound (Item 77, Appendix C)

Locknut (2) (Item 105, Appendix F)

a. Removal.

NOTE

Left and right bumper weldments

are identical. Right bumper

weldment is shown.

(1) Remove snapper pin (1) from bumper

weldment (2) and front support assembly

(3).

(2) Remove screw (4), two washers (5) and

bumper weldment (2) from front support

assembly (3).

2

3

1

5

4

2

3
TM 9-2320-364-20-5

21-206

21-41. CONTAINER HANDLING UNIT (CHU) BUMPER WELDMENT 

REPLACEMENT (CONT).

NOTE

• Shims may or may not be

present in Step (3).

• Note number of shims prior

to removal.

(3) Remove two locknuts (6), shim(s) (7) and

two bumpers (8) from bumper weldment (2).

Discard locknuts.

NOTE

Perform Step (4) only if wire rope

is damaged.

(4) Remove two swaging sleeves (9) and wire

rope (10) from bumper weldment (2) and

snapper pin (1).

b. Installation.

NOTE

• Left and right bumper

weldments are identical.

Right bumper weldment is

shown.

• Perform Steps (1) and (2)

only if wire rope was

removed.

(1) Position wire rope (10) through hole of

bumper weldment (2).

(2) Install two swaging sleeves (9) and wire

rope (10) on snapper pin (1) and bumper

weldment (2).

NOTE

Install shims as noted prior to

removal.

(3) Install two bumpers (8), shim(s) (7) and two

locknuts (6) on bumper weldment (2).

6

7

10

9

8

9

2

HOLE

1
TM 9-2320-364-20-5

 21-207

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(4) Apply sealing compound to threads of screw

(4).

(5) Position bumper weldment (2) on front

support assembly (3) and install two

washers (5) and screw (4).

(6) Tighten screw (4) until bottom washer is

tight against front support assembly (3).

(7) Loosen screw (4) 1/4 turn or until bumper

weldment (2) moves freely.

(8) Install snapper pin (1) and bumper weldment

(2) to front support assembly (3). 2

3

1

5

4

2

3
TM 9-2320-364-20-5

21-208

21-41. CONTAINER HANDLING UNIT (CHU) BUMPER WELDMENT 

REPLACEMENT (CONT).

c. Adjustment.

(1) Position lifting frame (1) in container mode

on truck using LHS (TM 9-2320-364-10).

(2) Measure gap between bail bar (2) and hook

(3) as shown.

NOTE

• Both rubber bumpers are

removed the same way. Right

side shown.

• Shims are 0.104 in. (2.7 mm)

thick.

• Add shims to decrease

clearance.

• Remove shims to increase

clearance.

• If gap is not 0.38 in. ± 0.25

in. (9.65 mm ± 6.35 mm),

perform Steps (3) through

(7).

• If gap is 0.38 in. ± 0.25 in.

(9.65 mm ± 6.35 mm), no

adjustment is necessary.

(3) Start engine (TM 9-2320-364-10).

(4) Using LHS, raise lifting frame (1)

approximately 12 in. (30 cm) off of rubber

bumpers (4).

(5) Shut OFF engine.

(6) Remove two locknuts (5) and rubber

bumpers (4) from bumper weldment (6).

Discard locknuts.

(7) Install two rubber bumpers (4), shim(s) (7),

as required, and two locknuts (5) on bumper

weldment (6).

(8) Repeat Steps (6) and (7) for left side.

3

4

1

2

0.38 IN. ± 0.25 IN.

(9.65 MM ± 6.35 MM)

7

5 6
TM 9-2320-364-20-5

 21-209

(9) Start engine (TM 9-2320-364-10).

(10) Position lifting frame on cone weldment

(TM 9-2320-364-10).

(11) Shut OFF engine (TM 9-2320-364-10).

d. Follow-on Maintenance:

• Lubricate CHU bumper weldment, (TM 9-2320-364-10).

• Install lifting frame on truck, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

21-210

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

21-42. CONTAINER HANDLING UNIT (CHU) AIR VALVE REPLACEMENT.

Materials/Parts

Sealing Compound (Item 72, Appendix C)

Tag, Identification (Item 88, Appendix C)

Lockwasher (3) (Item 156, Appendix F)

a. Removal.

NOTE

Left and right air valves are identical. Right air valve is shown.

(1) Remove three nuts (1), lockwashers (2), washers (3), air valve (4), data plate (5) and three screws (6) from

front support assembly (7). Discard lockwashers.

4

3

5

2

1

7 6
TM 9-2320-364-20-5

 21-211

NOTE

• Tag and mark air lines prior

to removal.

• Air lines 2502, 2504 and

2505 are to left air valve.

(2) Remove air line 2503 (8), air line 2506 (9)

and air line 2507 (10) from three elbows

(11).

(3) Remove three elbows (11) from air valve

(4).

(4) Remove two breather vents (12) from air

valve (4).

NOTE

Perform Step (5) if grommet is

damaged.

(5) Remove grommet (13) from front support

assembly (7).

b. Installation.

NOTE

• Left and right air valves are

identical. Right air valve is

shown.

• Perform Step (1) if grommet

was removed.

(1) Install grommet (13) in front support

assembly (7).

11

10

13

9

8

4 12

11

11

7
TM 9-2320-364-20-5

21-212

21-42. CONTAINER HANDLING UNIT (CHU) AIR VALVE REPLACEMENT (CONT).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(2) Apply sealing compound to threads of three

elbows (11) and two breather vents (12).

(3) Install three elbows (11) and two breather

vents (12) on air valve (4).

NOTE

• Air line 2502, 2504 and 2505

are to left air valve.

• Install air lines as noted prior

to removal.

(4) Install air line 2507 (10), air line 2506 (9)

and air line 2503 (8) to three elbows (11).

(5) Install air valve (4) and data plate (5) on

front support assembly (7) with three screws

(6), washers (3), lockwashers (2) and nuts

(1).

c. Follow-on Maintenance:

• Start engine, (TM 9-2320-364-10).

• Build air pressure to 125 psi (861 kPa).

• Shut OFF engine, (TM 9-2320-364-10).

• Check for air leaks.

• Check operation of rotary paddles, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

11

10

9

8

4 12

11

11

4

3

5

2

1

7 6
TM 9-2320-364-20-5

 21-213

21-43. CONTAINER HANDLING UNIT (CHU) AIR CYLINDER AND ROTARY PADDLE 

REPLACEMENT/ADJUSTMENT.

This task covers:

a. Removal c. Adjustment

b. Installation d. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Lifting frame removed from truck

(TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Pliers, Retaining Ring (Item 49, Appendix G)

Materials/Parts

Antiseize Compound (Item 20, Appendix C)

Sealing Compound (Item 77, Appendix C)

Tag, Identification (Item 88, Appendix C)

Locknut (3) (Item 101, Appendix F)

Materials/Parts - Continued

Locknut (Item 140, Appendix F)

Personnel Required

Two

a. Removal.

NOTE

• Tag and mark air lines prior to removal.

• Left and right air cylinders and rotary paddles are removed the same way. Right side is

shown.

• Air lines 2504 and 2505 are to left hand cylinder.

(1) Remove air line 2506 (1) and air line 2507 (2) from air cylinder (3).

(2) Remove two elbows (4) from air cylinder (3).

1

4

2

4

3
TM 9-2320-364-20-5

21-214

21-43. CONTAINER HANDLING UNIT (CHU) AIR CYLINDER AND ROTARY PADDLE REPLACEMENT (CONT).

(3) Remove locknut (5) and screw (6) from air

cylinder (3) and stow cone weldment (7).

Discard locknut.

Use care when removing snap

and retaining rings. Snap and

retaining rings are under spring

tension and can act as projectiles

when released and could cause

severe eye injury.

(4) Remove two retaining rings (8) and pin (9)

securing air cylinder (3) to rotary paddle

(10).

(5) Remove air cylinder (3) from stow cone

weldment (7).

(6) Remove rod clevis (11) from air cylinder (3).

5

8

11

6

7 3

3

9

10

8

3

7
TM 9-2320-364-20-5

 21-215

Use care when removing snap

and retaining rings. Snap and

retaining rings are under spring

tension and can act as projectiles

when released and could cause

severe eye injury.

(7) Remove retaining ring (12) and rotary

paddle (10) from rotary paddle bracket (13).

(8) Remove three locknuts (14), screws (15) and

rotary paddle bracket (13) from stow cone

weldment (7). Discard locknuts.

NOTE

Perform Step (9) if bearing is

damaged.

(9) Remove bearing (16) from rotary paddle

bracket (13).

b. Installation.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

NOTE

Left and right air cylinders and

rotary paddles are identical unless

noted. Right side is shown.

(1) Apply antiseize to outer surface of bearing

(16).

(2) Install bearing (16) in rotary paddle bracket

(13).

13

15

16

12

10

14

13

7

13
TM 9-2320-364-20-5

21-216

21-43. CONTAINER HANDLING UNIT (CHU) AIR CYLINDER AND ROTARY PADDLE REPLACEMENT (CONT).

(3) Install rotary paddle bracket (13) with three

screws (15) and locknuts (14) to stow cone

weldment (7).

Use care when installing snap and

retaining rings. Snap and

retaining rings are under spring

tension and can act as projectiles

when released and could cause

severe eye injury.

(4) Install rotary paddle (10) in rotary paddle

bracket (13) with retaining ring (12).

NOTE

Rod clevis will be tightened in c.

Adjustment.

(5) Position rod clevis (11) on air cylinder (3).

13

12

10

11

3

15

14

13

7
TM 9-2320-364-20-5

 21-217

(6) Position air cylinder (3) on rotary paddle

(10) and stow cone weldment (7).

Use care when installing snap and

retaining rings. Snap and

retaining rings are under spring

tension and can act as projectiles

when released and could cause

severe eye injury.

(7) Install rotary paddle (10) to air cylinder (3)

with pin (9) and two retaining rings (8).

(8) Install air cylinder (3) to stow cone

weldment (7) with screw (6) and locknut (5).

5

8

6

7 3

3

9

10

8
TM 9-2320-364-20-5

21-218

21-43. CONTAINER HANDLING UNIT (CHU) AIR CYLINDER AND ROTARY PADDLE REPLACEMENT (CONT).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(9) Apply sealing compound to threads of two

elbows (4).

(10) Install two elbows (4) on air cylinder (3).

NOTE

• Install air lines as noted prior

to removal.

• Air lines 2504 and 2505 are

to left hand cylinder.

(11) Install air line 2507 (2) and air line 2506 (1)

to air cylinder (3).

c. Adjustment.

NOTE

Left and right air cylinders and

rotary paddles are adjusted the

same. Right air cylinder and

rotary paddle are shown.

(1) Start engine (TM 9-2320-364-10).

(2) Build air pressure to 125 psi (861 kPa).

(3) Shut OFF engine (TM 9-2320-364-10).

(4) Check for air leaks.

(5) Check operation of right rotary paddle (1)

using right air valve (2).

1

4

2

4

3

1

2
TM 9-2320-364-20-5

 21-219

(6) Position lifting frame (3) in stow mode 

(TM 9-2320-364-10).

(7) With the aid of an assistant, position lifting

frame (3) using LHS, approximately 6 in.

(15 cm) before slot in flipper bracket (4)

engages with rotary paddle (1).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

NOTE

Shaft of air cylinder is loosened

and tightened by using wrench on

flats near clevis.

(8) Loosen shaft (5) on air cylinder (6) and

apply sealing compound to threads.

(9) Tighten shaft (5) on air cylinder (6) and

clevis (7) until rotary paddle (1) aligns with

slot in flipper bracket (4).

(10) Stow lifting frame (3) on truck and check

operation of flipper bracket (4) (TM

9-2320-364-10).

(11) Repeat Steps (6) through (10) as necessary.

d. Follow-on Maintenance:

• Position lifting frame on truck in container mode, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

1

3

6

5

7

4
TM 9-2320-364-20-5

21-220

21-44. CONTAINER HANDLING UNIT (CHU) STOW CONE WELDMENT 

REPLACEMENT.

This task covers:

a. Removal c. Adjustment

b. Installation d. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

CHU air cylinders and rotary paddles removed,

(Para 21-43)

Stow weldment removed, (Para 21-34)

Lifting frame removed from truck, 

(TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Lifting Device, Minimum Capacity 225 lbs

(102 kg)

Materials/Parts

Locknut (6) (Item 92, Appendix F)

Personnel Required

Two

a. Removal.

Stow cone weldment weighs approximately 225 lbs (102 kg). Attach suitable lifting device

to prevent possible injury to personnel.

(1) Attach lifting device to stow cone weldment (1).

(2) Remove six locknuts (2) and screws (3) from stow cone weldment (1) and front support assembly (4).

NOTE

• Shims may or may not be present in Step (3).

• Note quantity of shims prior to removal.

(3) Remove stow cone weldment (1) and shim(s) (5) from front support assembly (4).

(4) Remove lifting device from stow weldment (1).

2

3

1

5

4
TM 9-2320-364-20-5

 21-221

b. Installation.

Stow cone weldment weighs

approximately 225 lbs (102 kg).

Attach suitable lifting device to

prevent possible injury to

personnel.

NOTE

Install shims as noted prior to

removal.

(1) Position shim(s) (5) and stow weldment (1)

on front support assembly (4).

NOTE

Screws and locknuts will be

tightened in c. Adjustment

procedures.

(2) Position six screws (3) and locknuts (2) on

stow weldment (1) and front support

assembly (4).

c. Adjustment.

NOTE

• Measurements should be

taken on both sides of stow

cone weldment.

• If measurement “A” is not

18.1 in. (46 cm) ± 0.125 in.

(3.18 mm), perform Steps (3)

and (6).

• If measurement “A” is 18.1

in. (46 cm) ± 0.125 in. (3.18

mm), go to Step (2).

• Stow cone weldment shims

are already installed. Remove

shims as required.

(1) Measure distance between base of stow

cone weldment (1) and bottom of pivot pin

(2). Record as measurement “A”.

2

3

1

5

4

2

1

A
TM 9-2320-364-20-5

21-222

21-44. CONTAINER HANDLING UNIT (CHU) STOW WELDMENT 

REPLACEMENT (CONT).

NOTE

• Measurements should be

taken on both sides of cone

weldment.

• If measurement “B” is not

5.87 in. (15 cm) ± 0.125 in.

(3.18 mm), perform Steps (4)

through (6).

• If measurement “B” is 5.87

in. (15 cm) ± 0.125 in. (3.18

mm), go to Step (8).

(2) Measure distance between base of stow

cone weldment (1) and LHS hook arm (4).

Record as measurement “B”.

(3) Remove six locknuts (5), screws (6), stow

cone weldment (1) and shim(s), as required,

(7) from front support assembly (8).

Discard locknuts and shim(s).

(4) Remove six locknuts (5) and screws (6)

from cone weldment (1) and front support

assembly (8). Discard locknuts.

(5) Position stow cone weldment (1) to proper

position to achieve measurement “B”.

(6) Install stow cone weldment (1) and shim(s)

(7) on front support assembly (8) with six

screws (6) and locknuts (5).

(7) Repeat Steps (1) and (2).

(8) Remove lifting device from stow cone

weldment (1).

d. Follow-on Maintenance:

• Install remainder of stow weldment, (Para 21-34).

• Install CHU air cylinders and rotary paddles, (Para 21-43).

• Wheels chocked, (TM 9-2320-364-10).

END OF TASK

1

7

6

8 5

B

3
TM 9-2320-364-20-5

 21-223

21-45. CONTAINER HANDLING UNIT (CHU) FRONT CROSSMEMBER ASSEMBLY 

REPLACEMENT.

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Bumper weldment removed, (Para 21–42)

CHU air lines removed, (Para 12-36)

CHU air valves removed, (Para 21-42)

CHU air cylinders and rotary paddles removed,

(Para 21-43)

CHU stow cone weldment removed, (Para 21-44)

Deck weldment removed, (Para 21–41)

Auxiliary fuel tank removed (if equipped), 

(Para 4-9)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Lifting Device, Minimum Capacity 500 lbs

(227 kg)

Materials/Parts

Locknut (18) (Item 92, Appendix F)

Personnel Required

Two

a. Removal.

Front crossmember assembly weighs approximately 500 (227 kg). Attach suitable lifting

device to prevent possible injury to personnel.

(1) Attach lifting device to front crossmember assembly (1).

(2) Remove 18 locknuts (2) and screws (3) from front crossmember assembly (1), right front support bracket

(4) and left front support bracket (5). Discard locknuts.

(3) Remove front crossmember assembly (1) from support brackets (4) and (5).

(4) Position front crossmember assembly (1) on ground and remove lifting device.

1

2

4

5

3
TM 9-2320-364-20-5

21-224

21-45. CONTAINER HANDLING UNIT (CHU) FRONT CROSSMEMBER ASSEMBLY

REPLACEMENT (CONT).

b. Installation.

Front crossmember assembly

weighs approximately 500 (227

kg). Attach suitable lifting device

to prevent possible injury to

personnel.

(1) Attach lifting device to front crossmember

assembly (1).

(2) With the aid of an assistant, position front

crossmember assembly (1) on left front

support bracket (5) and right front support

bracket (4).

(3) Install front crossmember assembly (1) to

front support brackets (5) and (4) with 18

screws (3) and locknuts (2).

(4) Remove lifting device from front

crossmember assembly (1).

c. Follow-on Maintenance:

• Install auxiliary fuel tank (if equipped), (Para 4-9).

• Install deck weldment, (Para 21-40).

• Install CHU stow cone weldment, (Para 21-44).

• Install CHU air cylinders and rotary paddles, (Para 21-43).

• Install CHU air valves, (Para 21-42).

• Install CHU air lines, (Para 12-36).

• Install bumper weldment, (Para 21-41).

• Remove wheel chocks, (TM 9–2320–364–10).

END OF TASK

1

2

4

5

3
TM 9-2320-364-20-5

 21-225

21-46. CONTAINER HANDLING UNIT (CHU) FRONT SUPPORT BRACKETS 

REPLACEMENT.

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

CHU air lines removed, (Para 12-36)

CHU deck weldments removed, (Para 21-40)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Lifting Device, Minimum Capacity 660 lbs

(299 kg)

Materials/Parts

Locknut (29) (Item 92, Appendix F)

Locknut (10) (Item 93, Appendix F)

Personnel Required

Two

a. Removal.

Front support assembly weighs 660 lbs (299 kg). Attach suitable lifting device to prevent

possible injury to personnel.

(1) Attach lifting device to front support assembly (1).

(2) Remove 18 locknuts (2) and screws (3) from front support assembly (1), right front support bracket (4)

and left front support bracket (5). Discard locknuts.

(3) Remove front support assembly (1) from support brackets (4) and (5).

(4) Position front support assembly (1) on ground and remove lifting device.

2

5

3

4

1
TM 9-2320-364-20-5

21-226

21-46. CONTAINER HANDLING UNIT (CHU) FRONT SUPPORT BRACKETS 

REPLACEMENT (CONT).

Right front support bracket

weighs 98 lbs (44 kg). Attach

suitable lifting device to prevent

possible injury to personnel.

(5) Attach lifting device to right front support

bracket (4).

NOTE

Perform Steps (6) and (7) if truck

is equipped with auxiliary fuel

tank.

(6) Loosen bottom screw (6) and locknut (7) on

right hand bracket (8).

(7) Loosen two bottom screws (9) and locknuts

(10) on auxiliary fuel tank support (11).

NOTE

• Perform Step (8) for trucks

equipped with auxiliary fuel

tank.

• Perform Step (9) for trucks

not equipped with auxiliary

fuel tank.

(8) With the aid of an assistant, remove screw

(12), four screws (13), screw (14), six

locknuts (15), two screws (16), locknuts

(17), screw (18) and locknut (19) from right

front support bracket (4) and auxiliary fuel

tank support (11). Discard locknuts.

(9) With the aid of an assistant, remove six

screws (13), screw (14), seven locknuts (15),

two screws (16) and locknuts (17) from right

front support bracket (4). Discard locknuts.

(10) Remove right front support bracket (4) from

frame (20).

(11) Position right front support bracket (4) on

ground and remove lifting device.

6

11

4

13

16

19

20

12

17

18

15

8

15

10

9

14
TM 9-2320-364-20-5

 21-227

Left front support bracket weighs

98 lbs (44 kg). Attach suitable

lifting device to prevent possible

injury to personnel.

(12) Attach lifting device to left front support

bracket (5).

(13) Remove two screws (21), locknuts (22),

screw (23), five screws (24), screw (25) and

seven locknuts (26) from front support

bracket (5) and frame (20). Discard

locknuts.

(14) Loosen bottom front screw (27), rear

bottom screw (28) and two locknuts (29)

on air dryer bracket (30).

(15) With the aid of an assistant, remove 

left front support bracket (5) from 

frame (20).

(16) Position left front support bracket (5) on

ground and remove lifting device.

28 30

20

24

26

21

22 23

26

27

25 26

AIR DRYERS AND

FUEL WATER 

SEPARATOR

SHOWN REMOVED

FOR CLARITY

29

29
TM 9-2320-364-20-5

21-228

21-46. CONTAINER HANDLING UNIT (CHU) FRONT SUPPORT BRACKETS 

REPLACEMENT (CONT).

b. Installation.

Left front support bracket weighs

98 lbs (44 kg). Attach suitable

lifting device to prevent possible

injury to personnel.

(1) Attach lifting device to left front support

bracket (5).

(2) Position five screws (24), screw (23) and six

locknuts (26) to left front support bracket (5)

and frame (20). Do not tighten.

(3) Position two screws (21) and locknuts (22)

to left front support bracket (5) and frame

(20). Do not tighten.

(4) Position screw (25) and locknut (26) to left

front support bracket (5) and frame (20). Do

not tighten.

(5) Remove two locknuts (29) from screw (28)

and screw (27). Discard locknut.

(6) Position two locknuts (29) on screw (28)

and screw (27). Do not tighten.

(7) Tighten six locknuts (26), two locknuts (29)

and (22), locknut (26) on screw (27), (28),

(25) and (23), five screws (23) and two

screws (21).

(8) Remove lifting device from left front

support bracket (5).

28 30

20

24

26

21

22 23

26

27

25 26

AIR DRYERS AND

FUEL WATER 

SEPARATOR

SHOWN REMOVED

FOR CLARITY

29

29
TM 9-2320-364-20-5

 21-229

Right front support bracket

weighs 98 lbs (44.49 kg). Attach

suitable lifting device to prevent

possible injury to personnel.

(9) Attach suitable lifting device to right front

support bracket (4).

(10) With the aid of an assistant, position right

front support bracket (4) between frame

(20), bracket (8), auxiliary fuel tank support

(11) and rear fender support (31).

NOTE

• Ensure top front screw is

installed from the inside of

truck frame.

• Perform Step (11) for trucks

equipped with auxiliary fuel

tank.

• Perform Step (12) for trucks

not equipped with auxiliary

fuel tank.

(11) With the aid of an assistant, install screw

(12), four screws (13), screw (14), six

locknuts (15), two screws (16), locknuts

(17), screw (18) and locknut (19) from

auxiliary fuel tank support (11).

(12) With the aid of an assistant, install six

screws (13), six locknuts (15), two screws

(16), locknuts (17), screw (18) and locknut

(19) from auxiliary fuel tank support (11).

(13) Remove two locknuts (10) from screws (9).

Discard locknuts.

(14) Install two locknuts (10) on two screws (9).

(15) Remove lifting device from right front

support bracket (4).

11

4

13

16

19

20

12

17

18

15

8

15

10

9

14

31
TM 9-2320-364-20-5

21-230

21-46. CONTAINER HANDLING UNIT (CHU) FRONT SUPPORT BRACKETS 

REPLACEMENT (CONT).

Front support assembly weighs

660 lbs (299 kg). Attach suitable

lifting device to prevent possible

injury to personnel.

(16) Attach lifting device to front support

assembly (1).

(17) Position front support assembly (1) on right

support assembly (4) and left support

assembly (5).

(18) Install 18 screws (3) and locknuts (2) to

front support assembly (1), right front

support bracket (4) and left front support

bracket (5).

(19) Remove lifting device from front support

assembly (1).

c. Follow-on Maintenance:

• Install CHU air lines, (Para 12-36).

• Install CHU deck weldment, (Para 21-40).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

2

5

3

4

1
TM 9-2320-364-20-5

 21-231/(21-232 blank)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Lifting frame removed from truck, 

(TM 9-2320-364-10)

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

21-47. CONTAINER HANDLING UNIT (CHU) LIFTING FRAME STRAP REPLACEMENT.

Materials/Parts

Locknut (2) (Item 91, Appendix F)

a. Removal.

NOTE

There are two retaining straps.

Both are removed the same way.

Right side is shown.

(1) Loosen and remove hook end of retaining

strap (1) from strap stow bar (2) on lifting

frame stow bracket (3).

(2) Remove two locknuts (4), screws (5), strap

anchor (6) and retaining strap (1) from

lifting frame stow bracket (3). Discard

locknuts.

b. Installation.

NOTE

There are two retaining straps.

Both are installed the same way.

Right side is shown.

(1) Install retaining strap (1), strap anchor (6),

two screws (5) and locknuts (4) on lifting

frame stow bracket (3).

(2) Position hook end of retaining strap (1) on

strap stow bar (2) and tighten strap.

c. Follow-On Maintenance:

• Install lifting frame on truck, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

1

2

4

3

5

6

TM 9-2320-364-20-5

 22-1

CHAPTER 22

ARMAMENT MAINTENANCE

Para Contents Page

22-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1

22-2 Machine Gun Ring Replacement 22-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

22-3 Machine Gun Ring Rear Support Replacement 22-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

22-4 Machine Gun Ring Front Support Replacement 22-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

22-5 Machine Gun Platform Installation/Storage 22-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

22-6 Machine Gun Hatch Ring Replacement 22-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

22-1. INTRODUCTION.

This chapter contains maintenance instructions for removing, replacing, installing and adjusting components of the

special purpose kits as authorized by the Maintenance Allocation Chart (MAC) at the Unit Maintenance level.
TM 9-2320-364-20-5

22-2 

Materials/Parts

Locknut (12) (Item 91, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Lifting Device, Minimum Capacity 350 lbs

(159 kg)

22-2. MACHINE GUN RING REPLACEMENT.

a. Removal.

Machine gun ring weighs 295 lbs (134 kg). Attach suitable lifting device to prevent injury to

personnel.

(1) Attach lifting device to machine gun ring (1).

(2) Remove eight locknuts (2) and screws (3) from machine gun ring front support (4). Discard locknuts.

(3) Remove four locknuts (5) and screws (6) from machine gun ring rear support (7). Discard locknuts.

(4) With the aid of an assistant, remove machine gun ring (1) from machine gun ring front and rear supports

(4) and (7) and lower machine gun ring to ground.

(5) Remove lifting device from machine gun ring (1).
TM 9-2320-364-20-5

 22-3

b. Installation.

Machine gun ring weighs 295 lbs (134 kg). Attach suitable lifting device to prevent injury to

personnel.

(1) Attach lifting device to machine gun ring (1).

(2) With the aid of an assistant, position machine gun ring (1) on machine gun ring front and rear supports (4)

and (7).

(3) Position four screws (6) and locknuts (5) on machine gun ring rear support (7).

(4) Install eight screws (3) and locknuts (2) on machine gun ring front support (4).

(5) Tighten four locknuts (5) on screws (6).

(6) Remove lifting device from machine gun ring (1).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

22-4 

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Machine gun ring removed, (Para 22-2)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Wrench, Torque (0-175 lb-ft [0-237 N.

m])

(Item 95, Appendix G)

22-3. MACHINE GUN RING REAR SUPPORT REPLACEMENT.

Materials/Parts

Sealing Compound (Item 77, Appendix C)

Locknut (4) (Item 91, Appendix F)

Lockwasher (2) (Item 165, Appendix F)

a. Removal.

(1) Remove four locknuts (1), screws (2) and machine gun ring mount (3) from machine gun ring rear

support (4). Discard locknuts.

(2) Remove nut (5), lockwasher (6), washer (7), spacer (8), six spring washers (9), sleeve (10) and screw (11)

from power module right frame (12). Discard lockwasher.

(3) Remove screw (13), sleeve (14), six spring washers (15), machine gun ring rear support (4) and sleeve

spacer (16) from power module right frame (12) and cross tube (17).
TM 9-2320-364-20-5

 22-5

b. Installation.

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in a wellventilated area. If adhesive,

solvent, or sealing compound 

gets on skin or clothing, wash

immediately with soap and 

water.

(1) Apply sealing compound on threads of

screw (13).

(2) Install sleeve spacer (16) in cross tube (17).

(3) Position machine gun ring rear support (4)

on power module right frame (12) with

sleeve spacer (16), six spring washers (15),

sleeve (14) and screw (13).

(4) Apply sealing compound on threads of

screw (11).

(5) Install screw (11), sleeve (10), six spring

washers (9), spacer (8), washer (7),

lockwasher (6) and nut (5) on power

module right frame (12). Tighten to 170

lb-ft (230 N.

m).

(6) Tighten screw (13) to 128 lb-ft (174 N.

m).

(7) Install machine gun ring mount (3) on

machine gun ring rear support (4) with four

screws (2) and locknuts (1).

c. Follow-On Maintenance:

• Install machine gun ring, (Para 22-2).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

22-6 

Materials/Parts

Locknut (8) (Item 91, Appendix F)

Lockwasher (4) (Item 165, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Machine gun ring removed, (Para 22-2)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Lifting Device, Minimum Capacity 100 lbs

(45 kg)

22-4. MACHINE GUN RING FRONT SUPPORT REPLACEMENT.

a. Removal.

Machine gun ring front support

weighs 55 lbs (25 kg). Attach

suitable lifting device to prevent

injury to personnel.

(1) Attach lifting device to machine gun ring

front support (1).

(2) Remove four locknuts (2), screws (3) and

washers (4) from machine gun ring front

support (1). Discard locknuts.

(3) With the aid of an assistant, remove four

locknuts (5), screws (6), washers (7),

machine gun ring front support (1) and two

spacers (8) from skid plate (9). Discard

locknuts.
TM 9-2320-364-20-5

 22-7

(4) Remove four nuts (10), lockwashers (11),

screws (12), washers (13) and machine gun

ring front support channel (14) from left and

right front supports (15) and (16). Discard

lockwashers.

b. Installation.

(1) Install machine gun ring front support

channel (14), four washers (13), screws (12),

lockwashers (11) and nuts (10) on left and

right front supports (15) and (16).

Machine gun ring front support

weighs 55 lbs (25 kg). Attach

suitable lifting device to prevent

injury to personnel.

(2) With the aid of an assistant, position two

spacers (8), machine gun ring front

support (1), four washers (7), screws (6) 

and locknuts (5) on skid plate (9).

(3) Position four washers (4), screws (3) and

locknuts (2) on machine gun ring front

support (1).

(4) Tighten four locknuts (5) on screws (6).

(5) Tighten four locknuts (2) on screws (3).

c. Follow-On Maintenance:

• Install machine gun ring, (Para 22-2).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

22-8 

Materials/Parts

Locknut (5) (Item 91, Appendix F)

This task covers:

a. Installation b. Storage c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

22-5. MACHINE GUN PLATFORM INSTALLATION/STORAGE.

a. Installation.

(1) Remove eight screws (1) and right Electronic Control Box (ECB) cover (2) from right ECB (3).

(2) Remove eight screws (4) and heater access panel (5) from heater compartment (6).

(3) Remove five plugs (7) from right ECB (3) and heater control side panel (8).

(4) Install platform bracket (9) on right ECB (3) and heater control side panel (8) with five screws (10),

washers (11) and locknuts (12).
TM 9-2320-364-20-5

 22-9

(5) Release leg assembly (13) from spring

clip (14).

NOTE

Tilt platform assembly and fit tab

in slot in platform bracket.

(6) Position platform assembly (15) on platform

bracket (9).

(7) Extend leg assembly (13) out from platform

assembly (15).

(8) Lower platform assembly (15) to floor (16).

(9) Store strap (17) in glove compartment (18).

(10) Install heater access panel (5) on heater

compartment (6) with eight screws (4).

(11) Install right ECB cover (2) on right ECB (3)

with eight screws (1).
TM 9-2320-364-20-5

22-10 

22-5. MACHINE GUN PLATFORM INSTALLATION/STORAGE (CONT).

b. Storage.

(1) Raise platform assembly (1) and lower leg

assembly (2).

(2) Remove platform assembly (1) from

platform bracket (3).

(3) Position leg assembly (2) in spring clip (4).

(4) Store platform assembly (1) between

passenger seat (5) and cab (6).

(5) Remove strap (7) from glove

compartment (8).

(6) Secure platform assembly (1) by hooking

strap (7) in platform bracket (3) and angle

bracket (9).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 22-11

Materials/Parts

Gasket (Item 68, Appendix F)

Washer, Sealing (34) (Item 353, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Socket Set, 3/8 in. (Item 62, Appendix G)

Wrench, Torque (0 to 60 N.

m)

(Item 98, Appendix G)

22-6. MACHINE GUN HATCH RING REPLACEMENT.

a. Removal.

(1) Remove hatch cover (1) from hatch ring assembly (2).

(2) Remove 34 screws (3), sealing washers (4), hatch ring assembly (2) and gasket (5) from cab roof (6).

Discard sealing washers and gasket.
TM 9-2320-364-20-5

22-12 

22-6. MACHINE GUN HATCH RING REPLACEMENT (CONT).

b. Installation.

NOTE

Gaskets do not come preformed.

Five gasket strips must be cut in

the following lengths:

• 34 in. - two strips.

• 24 in. - one strip.

• 14 in. - one strip.

• 24-1/2 in. - one strip.

(1) Cut gasket (5) strips to correct lengths.

(2) Install gasket (5) strips, hatch ring

assembly (2), 34 sealing washers (4) and

screws (3) on cab roof (6). Tighten screws

to 204 lb-in (23 N.

m).

(3) Install hatch cover (1) on hatch ring

assembly (2).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK

34 IN.

(86.36 CM)

34 IN.

(86.36 CM)

24 1/2 IN.

(62.23 CM)

14 IN.

(35.56 CM)

24 IN.

(60.96 CM)
TM 9-2320-364-20-5

 23-1

CHAPTER 23

GAGES (NON-ELECTRICAL) MAINTENANCE

Para Contents Page

23-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1

23-2 Air Pressure Indicator Replacement 23-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

23-3 Air Restriction Indicator Replacement 23-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

23-1. INTRODUCTION.

This chapter contains maintenance instructions for removing, replacing and installing non-electrical gages as authorized

by the Maintenance Allocation Chart (MAC) at the Unit Maintenance level.
TM 9-2320-364-20-5

23-2 

Materials/Parts

Sealing Compound (Item 73, Appendix C)

Tags, Identification (Item 88, Appendix C)

Lockwasher (2) (Item 183, Appendix F)

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Air system drained, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

23-2. AIR PRESSURE INDICATOR REPLACEMENT.

a. Removal.

(1) Remove eight screws (1) and sunshield (2)

from dash (3) and air dash panel assembly

(4).

NOTE

• Tag and mark all lines prior

to removal.

• Note position of elbows prior

to removal.

(2) Remove two screws (1) from air dash panel

assembly (4) and tilt air dash panel

assembly (4) forward.

(3) Remove light socket (5) from rear of air

pressure indicator (6).

(4) Remove air line 2641 (7) and air line

2610 (8) from two adapters (9).

(5) Remove two adapters (9) from elbows (10).

(6) Remove two elbows (10) from rear of air

pressure indicator studs (11).

(7) Remove two nuts (12), lockwashers (13) and

air pressure indicator mounting bracket (14)

from air pressure indicator (6). Discard

lockwashers.

(8) Remove air pressure indicator (6) from air

dash panel assembly (4).
TM 9-2320-364-20-5

 23-3

b. Installation.

NOTE

During installation, ensure face of

gage is aligned properly.

(1) Position air pressure indicator (6) in air dash

panel assembly (4).

(2) Install air pressure indicator mounting

bracket (14), two lockwashers (13) and

nuts (12) on rear of air pressure indicator (6).

Adhesives, solvents, and sealing

compounds can burn easily, can

give off harmful vapors, and are

harmful to skin and clothing. To

avoid injury or death, keep away

from open fire and use in

well-ventilated area. If adhesive,

solvent, or sealing compound gets

on skin or clothing, wash

immediately with soap and water.

(3) Apply sealing compound to threads of air

pressure indicator studs (11).

NOTE

Install elbows as noted during

removal.

(4) Install two elbows (10) on air pressure

indicator studs (11).

(5) Apply sealing compound to threads of two

elbows (10).

(6) Install two adapters (9) on elbows (10).

(7) Install air line 2641 (7) and air line 2610 (8)

on two adapters (9).

(8) Install light socket (5) on rear of air pressure

indicator (6).

(9) Install two screws (1) on air dash panel

assembly (4).

(10) Install sunshield (2) on dash (3) and air

dash panel assembly (4) with eight screws

(1).
TM 9-2320-364-20-5

23-4 

23-2. AIR PRESSURE INDICATOR REPLACEMENT (CONT).

c. Follow-On Maintenance:

• Start engine, (TM 9-2320-364-10).

• Build air pressure to 125 psi (861 kPa).

• Shut OFF engine, (TM 9-2320-364-10).

• Check for air leaks, (TM 9-2320-364-10).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 23-5

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

23-3. AIR RESTRICTION INDICATOR REPLACEMENT.

a. Removal.

(1) Remove six screws (1) and sunshield (2) from dash (3) and air dash panel (4).

(2) Remove two screws (1) from air dash panel (4).

(3) Pull air dash panel (4) away from dash (5).

(4) Remove two screws (6) from gage face (7).

(5) Remove gage face (7) from restriction indicator (8).

Ensure instrument panel is only pulled away from dash far enough to route restrictor indicator between

instrument panel and dash. If instrument panel is pulled away further than necessary, damage to

equipment may result.

(6) Route restrictor indicator (8) up between air dash panel (4) and dash (5).

(7) Remove restrictor indicator (8) from hose (9).

(8) Disconnect MC125 connector (10).

NOTE

Perform Step (9) if replacing light kit.

(9) Remove two screws (11) and light kit (12) from restrictor indicator (8).
TM 9-2320-364-20-5

23-6 

23-3. AIR RESTRICTION INDICATOR REPLACEMENT (CONT).

b. Installation.

NOTE

Perform Step (1) if light kit was

removed.

(1) Install light kit (12) on restrictor indicator

(8) using two screws (11).

(2) Pull air dash panel (4) away from dash (5).

(3) Connect MC125 connector (10).

(4) Install restrictor indicator (8) on hose (9).

Ensure air dash panel is only

pulled away from dash far enough

to route restrictor indicator

between air dash panel and dash.

If air dash panel is pulled away

further than necessary, damage

may result to equipment.

(5) Route restrictor indicator (8) down through

air dash panel (4) and dash (5).

NOTE

Ensure restrictor indicator is

positioned in upright position in

air dash panel.

(6) Position restrictor indicator (8) in air dash

panel (4).

(7) Install gage face (7) in air dash panel (4)

with two screws (6).

(8) Position air dash panel (4) on dash (5).

(9) Install two screws (1) in air dash panel (4).

(10) Install sunshield (2) on dash (3) and air

dash panel (4) with six screws (1).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 24-1

CHAPTER 24

CHEMICAL, BIOLOGICAL AND RADIOLOGICAL (CBR) 

MAINTENANCE

Para Contents Page

24-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-1

24-2 Gas Particulate Filter Unit Kit Mounting/Installation 24-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

24-3 Decontamination Kit Bracket Replacement 24-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

24-1. INTRODUCTION.

This chapter contains maintenance instructions for removing, installing and servicing components of the chemical,

biological and radiological (CBR) equipment as authorized by the Maintenance Allocation Chart (MAC) at the Unit

Maintenance level.
TM 9-2320-364-20-5

24-2 

This task covers:

a. Installation b. Follow-On Maintenance

INITIAL SETUP

Personnel Required

Two

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Electronic Control Box (ECB) cover removed,

(Para 17-22)

Electronic Control Box (ECB) side panel

removed, (Para 17-20)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

24-2. GAS PARTICULATE FILTER UNIT KIT MOUNTING/INSTALLATION.

Materials/Parts

Locknut (2) (Item 91, Appendix F)

Locknut (Item 120, Appendix F)

Lockwasher (Item 171, Appendix F)

a. Installation.

(1) Remove blank insert (1) from Electronic

Control Box (ECB) side panel (2).

(2) Install gas particulate filter switch S19 (3) in

ECB side panel (2).

(3) Install lamp (4) in bottom of gas particulate

filter switch S19 (3).

(4) Connect wire harness MC58 connector (5) to

gas particulate switch S19 (3).

(5) Install applique (6) on front of gas

particulate switch S19 (3).
TM 9-2320-364-20-5

 24-3

(6) Remove hole plug (7) from back of ECB (8).

(7) Install grommet (9) on wire harness (10).

(8) Install wire harness (10) and grommet (9) in

back of ECB (8).

(9) Connect wire harness MC58 connector (5)

inside of ECB (8).

NOTE

Keep cushion clip and mounting

hardware to secure wire harness 

to gas particulate filter bracket,

when installed.

(10) With the aid of an assistant, remove

screw (11) and locknut (12) from dome

light bracket (13).

(11) With the aid of an assistant, install two

ground wires 1435 (14) on dome light

bracket (13) with screw (11) and

locknut (12).

(12) With the aid of an assistant, remove

screw (15) and locknut (16) from dome

light bracket (13).

(13) With the aid of an assistant, install ground

wire 1435 (17) on dome light bracket (13)

with screw (15) and locknut (16).
TM 9-2320-364-20-5

24-4 

24-2. GAS PARTICULATE FILTER UNIT KIT MOUNTING/INSTALLATION (CONT).

(14) Remove two screws (18) from cab frame (19).

(15) Install bracket (20) on cab frame (19) with two screws (18).

(16) Install screw (21) in bracket (20) with washer (22) and locknut (23).

b. Follow-On Maintenance:

• Install Electronic Control Box (ECB) side panel, (Para 17-20).

• Install Electronic Control Box (ECB) cover, (Para 17-22).

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

 24-5

This task covers:

a. Removal b. Installation c. Follow-On Maintenance

INITIAL SETUP

Materials/Parts

Locknut (8) (Item 140, Appendix F)

Equipment Condition

Engine OFF, (TM 9-2320-364-10)

Wheels chocked, (TM 9-2320-364-10)

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive

(Item 74, Appendix G)

Wrench, Torque (0 to 175 lb-ft [0-237 N.

m])

(Item 95, Appendix G)

24-3. DECONTAMINATION KIT BRACKET REPLACEMENT.

a. Removal.

(1) Remove strap (1) and decontamination can (2) from bracket (3).

(2) Remove two locknuts (4) and screws (5) from box assembly (6). Discard locknuts.

(3) Remove two locknuts (7), screws (8) and pull decontamination assembly from box assembly (6). 

Discard locknuts.

(4) Install four plugs (9) into box assembly (6).

(5) Remove four locknuts (10), screws (11) and two brackets (12) from bracket (3). Discard locknuts.
TM 9-2320-364-20-5

24-6 

24-3. DECONTAMINATION KIT BRACKET REPLACEMENT (CONT).

b. Installation.

(1) Install two brackets (12) on bracket (3) with

four screws (11) and locknuts (10). Tighten

locknuts to 45 lb-ft (61 N.

m).

(2) Remove four plugs (9) from box

assembly (6).

(3) Install two brackets (12) on box assembly (6)

and secure with two screws (8) and

locknuts (7).

(4) Install two screws (5) and locknuts (4) in box

assembly (6).

(5) Tighten locknuts (4) and (7) to 45 lb-ft

(61 N.

m).

(6) Install decontamination can (2) in 

bracket (3) and secure with strap (1).

c. Follow-On Maintenance:

• Remove wheel chocks, (TM 9-2320-364-10).

END OF TASK
TM 9-2320-364-20-5

A-1

APPENDIX A

REFERENCES

A-1. SCOPE.

Indexes should be consulted frequently for latest changes or revisions of references given in this appendix and for new

publications relating to material covered in this publication.

Military Publication Indexes.

Consolidated Index of Army Publications and Forms DA PAM 310-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

A-2. FORMS.

Refer to DA PAM 738-750, The Army Maintenance Management System (TAMMS), for instructions on the use of

maintenance forms pertaining to the vehicle.

A-3. FIELD MANUALS.

The following publications contain information pertinent to the vehicle material.

Camouflage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 20-3

Manual for Wheel Vehicle Driver FM 21-305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Nuclear, Biological, and Chemical Defense FM 21-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Basic Cold Weather Manual FM 31-70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Northern Operations FM 31-71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Chemical, Biological, and Radiological (CBR) Decontamination FM 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Nuclear, Biological, and Chemical (NBC) Reconnaissance and Decontamination 

 Operations (How to Fight) FM 3-87 (HTF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Army Motor Transport Units and Operations FM 55-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Operation and Maintenance of Ordnance Materiel in Cold Weather 0°F to -65°F FM 9-207 . . . . . . . . . . . . . . . . . . . . . . . . 

A-4. TECHNICAL MANUALS.

Painting Instructions TM 43-0139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

General Shop Practice Requirements for Repair, Maintenance, and

Test of Electronic Equipment TM 43-0158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
TM 9-2320-364-20-5

A-2 

A-4. TECHNICAL MANUALS (CONT).

Procedures for Destruction of Tank Automotive Equipment to Prevent

Enemy Use (U.S. Army Tank-Automotive Command) TM 750-244-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Inspection, Care, and Maintenance of Antifriction Bearings TM 9-214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Materials Used for Cleaning, Preserving, Abrading, and Cementing

Ordinance Material and Related Materials Including Chemicals TM 9-247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Operator/Unit/Direct Support/General Support Maintenance Manual

for Care, Maintenance, Repair, and Inspection of Pneumatic

Tires and Inner Tubes TM 9-2610-200-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Operator’s and Organizational Maintenance Manual Including Repair Parts and 

Special Tools List for Simplified Test Equipment for Internal

Combustion Engines TM 9-4910-571-12&P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Maintenance and Repair for Lead-Acid Storage Batteries TM 9-6140-200-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

A-5. MISCELLANEOUS PUBLICATIONS.

Description, Use, Bonding Techniques, and Properties of Adhesives TB ORD1032 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Safety Inspection and Testing of Lifting Devices TB 43-0142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Operator’s Circular for Welding Theory and Application TC 9-237 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
TM 9-2320-364-20-5

B-1

APPENDIX B

MAINTENANCE ALLOCATION CHART (MAC)

Section I. INTRODUCTION

B-1. GENERAL.

a. This section provides a general explanation of all maintenance and repair functions authorized at various

maintenance levels.

b. The Maintenance Allocation Chart (MAC) in Section II designates overall authority and responsibility for

the performance of maintenance functions on the identified end item or component. The application of the

maintenance functions to the end item or component will be consistent with the capacities and capabilities of the

designated maintenance levels.

c. Section III lists the tools and test equipment required for each maintenance function as referenced from 

Section II.

d. Section IV lists remarks (identified by an alphabetic code in Column 6 of the MAC) to provide a ready 

reference to the definition of the remark.

B-2. MAINTENANCE FUNCTIONS.

Maintenance functions will be limited to and defined as follows:

a. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or

electrical characteristics with established standards through examination (e.g., by sight, sound, or feel).

b. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical

characteristics of an item and comparing those characteristics with prescribed standards.

c. Service. Operations required periodically to keep an item in proper operating condition, i.e., to clean 

(includes decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemical 

fluids, or gases.

d. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper or exact position, or by

setting the operating characteristics to specified parameters.

e. Align. To adjust specified variable elements of an item to bring about optimum or desired performance.

f. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test,

measuring, and diagnostic equipments used in precision measurement. Consists of comparisons of two

instruments, one of which is a certified standard of known accuracy, to detect and adjust any discrepancy in the

accuracy of the instrument being compared.

g. Remove/Install. To remove and install the same item when required to perform service or other

maintenance functions. Install may be the act of emplacing, seating, or fixing into position a spare, repair part, or

module (component or assembly) in a manner to allow the proper functioning of an equipment or system.
TM 9-2320-364-20-5

B-2 

h. Replace. To remove an unserviceable item and install a serviceable counterpart in its place. “Replace” is

authorized by the MAC and is shown as the 3rd position code of the SMR code.

i. Repair. The application of maintenance services, including fault location/troubleshooting, 

removal/installation, and disassembly/assembly procedures, and maintenance actions to identify troubles and

restore serviceability to an item by correcting specific damage, fault, malfunction, or failure in a part,

subassembly, module (component or assembly), end item, or system.

(1). Service includes inspection, testing, service, adjustment, alinement, calibration and/or replacement.

(2). Fault locate/troubleshooting is the process of investigating and detecting the cause of equipment

malfunctioning; the act of isolating a fault within a system or Unit Under Test (UUT).

(3). Disassemble/Assemble encompasses the step-by-step taking apart (or breakdown) of a spare/functional

group coded item to the level of its least componency identified as maintenance significant (i.e., assigned

an SMR code) for the category of maintenance under consideration.

(4). Actions include welding, grinding, riveting, straightening, facing, remachining and/or resurfacing.

j. Overhaul. The maintenance effort (service/action) prescribed to restore an item to a completely

serviceable/operational condition as required by maintenance standards in appropriate technical publications (i.e.,

DMWR). Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul does not 

normally return an item to like new condition.

k. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a

like new condition in accordance with original manufacturing standards. Rebuild is the highest degree of material

maintenance applied to Army equipment. The rebuild operation includes the act of returning to zero those age

measurements (hours/miles, etc.) considered in classifying Army equipment/components.

B-3. EXPLANATION OF COLUMNS IN SECTION II.

a. Column 1, Group Number. Column 1 lists functional group code numbers, the purpose of which is to

identify maintenance significant components, assemblies, subassemblies, and modules with the next higher

assembly. End item group number shall be “OO.”

b. Column 2, Component/Assembly. Column 2 contains the names of components, assemblies,

subassemblies, and modules for which maintenance is authorized.

c. Column 3, Maintenance Function. Column 3 lists the functions to be performed on the item listed in

Column 2.
TM 9-2320-364-20-5

B-3

d. Column 4, Maintenance Level. Column 4 specifies, by the listing of a work time figure in the

appropriate subcolumn(s), the level of maintenance authorized to perform the function listed in Column 3. This

figure represents the active time required to perform that maintenance function at the indicated level of

maintenance. If the number or complexity of the tasks within the listed maintenance function vary at different

maintenance levels, appropriate work time figures will be shown for each level. The work time figure represents

the average time required to restore an item (assembly, subassembly, component, module, end item, or system) to

a serviceable condition under typical field operating conditions. This time includes preparation time (including

any necessary disassembly/assembly time), troubleshooting/fault location time, and quality assurance/quality

control time in addition to the time required to perform the specific tasks identified for the maintenance functions

authorized in the maintenance allocation chart. The symbol designations for the various maintenance levels are as

follows:

C Operator or Crew H General Support Maintenance

O Unit Maintenance D Depot Maintenance

F Direct Support Maintenance

* Asterisk indicates level of maintenance authorized to complete this function. No time is established.

e. Column 5, Tools and Equipment. Column 5 specifies, by code, those common tool sets (not individual

tools) and special tools, TMDE, and support equipment required to perform the designated function.

f. Column 6, Remarks. This column shall, when applicable, contain a letter code in alphabetic order,

which shall be keyed to the remarks contained in Section IV.

B-4. EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT 

REQUIREMENTS, SECTION III.

a. Column 1, Reference Code. The tool and test equipment reference code correlates with a code used in

the MAC, Section II, Column 5.

b. Column 2, Maintenance Level. The lowest category of maintenance authorized to use the tool or test

equipment.

c. Column 3, Nomenclature. Name or identification of the tool or test equipment.

d. Column 4, National Stock Number. The national stock number of the tool or test equipment.

e. Column 5, Tool Number. The manufacturers part number.

B-5. EXPLANATION OF COLUMNS IN REMARKS, SECTION IV.

a. Column 1, Reference Code. An alphabetic code listed in the sixth column of the MAC and first column

of the Remarks section to identify remarks made to the MAC.

b. Column 2, Remarks. The complete text of the remarks made to the MAC.
TM 9-2320-364-20-5

B-4 

Section II. MAINTENANCE ALLOCATION CHART 

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

01 ENGINE

 0100 Engine Assembly:

Engine Assembly Inspect

Test

Service

Adjust

Replace

Repair

Overhaul

0.4

1.0

1.0

2.0

21.5

44.4

*

23, 31,148

1, 126

5, 6, 79

5, 6, 7,205

5, 14,

86, 179

A

B

D

 0101 Crankcase, Block,

Cylinder Head:

Cylinder Block

Assembly

Replace

Repair

4.0

3.0 5, 6,10,12,

67, 81, 

97, 117, 

133, 166, 

187

Cylinder Head

Assembly (One)

Replace

Repair

17.7

3.0

5, 6,41,62,

100, 128

5, 6, 10,

29, 64

Cylinder Liner Replace

Repair

1.0

2.0

5, 155

5, 6,10,28,

67, 68, 87

C

C

 0102 Crankshaft:

Crankshaft and Main

Bearing

Replace

Repair

6.8

*

5, 6, 144,

5, 6, 24,26 C

Crankcase Front Cover

and Oil Seal

Inspect

Replace

0.2

6.5

5, 6, 107

 0103 Flywheel Assembly:

Flexplate Assembly Replace

Repair

25.9

*

5, 6
TM 9-2320-364-20-5

B-5

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

 0103 Flywheel Assembly -

CONT:

Rear Oil Seal Inspect

Replace

0.2

26.2 5, 6, 53,

81, 102, 

163

 0104 Pistons, Connecting

Rods:

Piston and

Connecting Rod

Replace

Repair

4.4

*

5, 37, 155

5, 6,10,22,

46, 73,115

C

 0105 Valves, Camshafts and

Timing System:

Rocker Covers Replace

Repair

3.2

*

1, 2, 4

5, 6, 10 C

Exhaust Valve Bridge Replace

Repair

7.1

*

5, 6

5, 6, 10 C

Exhaust Bridge Guide Repair * 5, 6, 113,

151, 156

C

Exhaust Valve Replace

Repair

25.6

*

5,6,10,100

5, 6,42,95,

106, 179

C

Exhaust Valve Guide Repair * 5, 100,157 C

Valve Seat Insert Repair * 5, 116,153 C

Camshaft Assembly Replace

Repair

1.5

*

5, 6

5, 6, 10 C

Cam Follower/

Push Rod

Replace

Repair

23.5

*

5, 6

5, 6, 10 C

Rocker Arm Replace

Repair

5.4

0.5

5

5, 6, 10

Idler Gear Assembly Replace

Repair

0.5

0.3

5, 6

5,6,10,130
TM 9-2320-364-20-5

B-6 

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

 0106 Engine Lubrication

System:

Adapter Assembly,

Oil Filter

Replace

Repair

1.1

*

1, 2

2, 4 C

Oil Cooler Assembly,

Engine

Replace

Test

4.9

*

5, 6

5, 6, 10 A

 0108 Manifolds:

Exhaust Manifold Inspect

Replace

0.3

4.6 5, 6

 0112 Engine Brake:

Engine Brake Retarder Adjust

Replace

Repair

0.9

4.2

*

5

5, 6

5, 6, 10 C

03 FUEL SYSTEM

 0301 Carburetor, Fuel

Injector:

Fuel Injector Adjust

Test

0.5

1.5

5

1, 4, 5, 31,

42, 91,148

Replace 4.9 5, 6, 30,

208

 0302 Fuel Pumps:

Fuel Pump Assembly Replace 3.2 5, 6, 20

Fuel Pump, Priming Replace 1.5 1, 2, 30

 0304 Air Cleaner:

Air Cleaner Assembly Replace

Repair

1.6

2.8

1, 4

1, 2, 4

 0305 Supercharger, Blower,

Turbocharger or

Altitude Compensator:

Blower Assembly Replace

Repair

12.1

3.0

5, 6, 20

5, 6,10,14,

117, 189

Blower Drive

Assembly

Replace

Repair

12.4

1.0

5, 6

5, 6, 10
TM 9-2320-364-20-5

B-7

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

 0305 Supercharger, Blower,

Turbocharger or

Altitude Compensator -

CONT:

Turbocharger

Assembly

Inspect

Replace

Repair

0.1

5.6

2.0

5, 6

5, 6,10,61,

89, 132

 0306 Tanks, Lines, Fittings,

Headers:

Fuel Lines and Fittings

(each)

Inspect

Replace

0.1

0.2

1, 30

 0309 Fuel Filters:

Fuel Strainer Service 0.1 1, 4

Fuel/Water Separator Inspect

Service

Replace

Repair

0.1

0.4

2.0

0.8

1, 2, 30

1, 2, 30

5, 6

 0311 Engine Starting Aids:

Ether Starting Aid Replace 1.0 1

04 EXHAUST SYSTEM

 0401 Muffler and Pipes:

Muffler Inspect

Replace

0.1

1.9 1, 2, 4

Pipes Inspect

Replace

0.1

1.5 1

05 COOLING SYSTEM

 0501 Radiator, Evaporative

Cooler or Heat

Exchanger:

Cooling Assembly Inspect

Test

Replace

0.1

0.2

1.9

1, 15, 186

1, 2, 4, 30,

126

Radiator Service

Test

Replace

Repair

0.3

6.6

0.5

1.0

1, 2, 52

186

1, 2, 4, 30,

126

5, 6, 30
TM 9-2320-364-20-5

B-8 

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

0503 Water Manifold,

Headers, Thermostats and Housing

Gaskets:

Right Thermostat

Housing

Replace 8.4 5, 6, 84,

109

Left Thermostat,

Housing

Replace 2.4 5, 6, 84,

109

Cooling System Hoses

and Tubes (each)

Inspect

Replace

0.1

0.4 1, 4, 30

Aftercooler Inspect

Replace

*

13.1 5, 6

A

0504 Water Pump:

Water Pump Assembly Replace

Repair

2.0

0.6

5, 6, 30

5, 6,15,49,

84, 114, 

143, 158

0505 Fan Assembly:

Fan Inspect

Adjust

Replace

0.1

0.5

1.9 5, 6

Fan Control

Solenoid Valve

Inspect

Test

Replace

0.1

0.5

0.5

1

1, 30, 126

06 ELECTRICAL

SYSTEM

0601 Generator, Alternator:

Alternator Assembly Test

Replace

Repair

0.3

2.0

3.2

2

1, 2, 65

6, 8, 10

Alternator Belts Inspect

Adjust

Replace

0.1

0.2

1.2

1, 2, 65

1, 2, 65
TM 9-2320-364-20-5

B-9

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

 0602 Generator Alternator

(Voltage):

Voltage Regulator Adjust

Test

Replace

0.3

0.5

0.1

1, 4

4

1

A

Polarity Protection

Control (145 AMP)

Adjust

Test

Replace

0.3

0.5

1.5

1, 4

4

1

A

Polarity Protection

Control (200 AMP)

Test

Replace

0.5

1.5

4

1 A

 0603 Starting Motor:

Starter Motor Test

Replace

Repair

0.3

2.6

4.0

4

1, 2, 4

6, 8, 10

 0607 Instrument or Engine

Control Panel:

Instrument Panel

Gages Wire Harness

Replace

Repair

2.5

*

1

C,E

Instrument Panel

Switch Wire Harness

Replace

Repair

1.0

*

1

C,E

 0608 Miscellaneous Items:

Ether Start Aid

Switch

Service

Replace

0.4

1.2 1

Crane Junction Box Replace

Repair

2.0

1.0

5, 6 

5, 6

Proximity Switches

(LHS) (each)

Replace

Adjust

Test

0.5

*

0.5

1, 2, 71

1, 4

C

Proximity Switch

(Outrigger)

Replace

Adjust

Test

0.5

*

0.5

1

1, 2

C
TM 9-2320-364-20-5

B-10 

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

 0609 Lights:

Head Light Assembly

(each)

Inspect

Adjust

Replace

0.1

0.2

0.2

1

1, 4

Lights (each) Inspect

Replace

Repair

0.1

0.5

*

1

1, 4 C

Work Lamps Replace

Repair

1.0

0.3

1, 4

1, 4

 0610 Sending Units and

Warning Switches:

Engine Cold

Plate/ECM

Inspect

Test

Replace

0.2

*

2.0

1, 4, 23,

31, 148

1, 2, 4, 42

A

Warning Buzzer Inspect

Replace

0.1

0.5 1

TRS/SRS Replace

Test

Adjust

3.0

*

*

5, 6

1,4,23,31,

32, 148

88, 194

A

A

Engine Throttle Sensor Test

Replace

0.3

0.8

1,4,23,31,

32, 148

1

Fuel Temperature

Sensor

Test

Replace

0.4

0.4

1,4,23,31,

32, 148

1

Engine Water

Temperature Sensor

Test

Replace

0.3

0.5

1, 4

1

Engine Oil

Temperature Sensor

Test

Replace

0.3

0.5

1, 4

1, 2

DDEC Engine Oil

Pressure Sensor

Test

Replace

0.3

0.5

1,4,23,31,

32, 42,148

1, 2

Manifold Pressure

Sensor

Test

Replace

0.3

0.5

1,4,23,31,

32, 148

1, 4
TM 9-2320-364-20-5

B-11

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

 0610 Sending Units and

Warning SwitchesCONT:

Engine Fuel Pressure

Sensor

Test

Replace

0.3

1.0

1, 4

1

Transmission

Electronic

Control Unit (ECU)

Test

Replace

0.5

1.0

1, 4

1

Magnetic Speed

Sensor

Test

Replace

0.3

0.7

5

5, 6

Tachometer Drive

Assembly

Test

Replace

*

1.1 1

A

Sending Units (each) Test

Replace

*

0.5 1, 4

A

EPAC Test

Adjust

Replace

*

*

*

5, 6

5

5

A

C

C

Differential Pressure

Switch

Test

Replace

*

0.9 11, 2, 4,30

A

 0611 Horn, Siren:

Electric Horn Replace 0.2 1

Horn Relay Replace 0.4 1

Horn Button Replace 0.1 1 C

 0612 Batteries, Storage

(Wet or Dry):

Batteries Inspect

Test

Service

Replace

0.1

0.3

0.3

1.0

1,4,23,31,

32, 42,148

1, 4

1

Battery Box Assembly Inspect

Replace

Repair

0.1

1.6

1.0

1

1, 2
TM 9-2320-364-20-5

B-12 

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

 0613 Hull or Chassis

Wiring Chassis

Engine Wiring Harness Test

Replace

Repair

*

*

12.0

*

1,4,23,31,

32, 42,148

5

1, 4, 45,96

A

F

C,E

DDEC Power Wiring

Harnesses

Test

Replace

Repair

*

0.5

0.5

1,4,23,31,

32, 148

5, 42

1,4, 42,43,

44, 56, 57,

183, 184, 

185, 197, 

198

A

Cab Wiring Harness Test

Replace

Repair

*

*

12.0

*

1,4,23,31,

32, 42,148

2, 5

1,4,45,96

A

F

C,E

STE/ICE Wiring

Harness

Test

Replace

Repair

*

*

2.0 5

1,4,45,96

A

F

C,E

Chassis Wiring

Harness

Test

Replace

Repair

*

*

4.0

*

5

1,4,45,96

A

F

C,E

Crane Wiring Replace

Repair *

* 5

1, 4

C

C,E

LHS/Cab

Interface Harness

Replace

Repair 0.5

0.8 5

1,4,45,96

07 TRANSMISSION

 0705 Transmission Shifting

Components

Transmission Shift

Selector

Replace

Repair

0.4

0.2

1

1

Electronic Shifter

Harness

Replace * 5, 6 C
TM 9-2320-364-20-5

B-13

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

 0710 Transmission Assy:

Flywheel Replace

Repair

0.8

0.2

5, 6,

121, 127

5, 6

Torque Convertor

Stator

Replace

Repair

1.0

*

5, 10, 86

C

Torque Converter

Housing

Replace

Repair

0.6

0.3

5, 6

5,6,10, 41,

73, 82, 83,

99, 108,

127,152

G

Torque Converter

Pump

Replace

Repair

1.0

0.3

5, 6, 142,

164

5, 10, 150 G

Transmission

Assembly

Inspect

Test

Service

Replace

Repair

Overhaul

0.1

0.5

1.0

*

3.0 27.4

*

5, 6, 32,

85, 148

1,2,4,126

5, 6

5,6,30,61,

86, 177

A

B

D

Output Shaft

Assembly

Replace

Repair

0.2

0.2

5

5, 6

Rear Transmission

Cover Assembly

Replace

Repair

0.2

*

5, 6

5,6,10,41,

83, 99,

104, 111,

137

C

Transmission Yoke/

Dust Shield/Oil Seal

Replace 3.0 5, 6,16,84,

103, 143, 

169

 0713 Intermediate Clutch:

First Clutch Assembly Replace

Repair

0.1

*

5

5,6,10,

101

C

Adapter Housing Replace

Repair

0.2

*

5

5, 6 C
TM 9-2320-364-20-5

B-14 

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

 0713 Intermediate ClutchCONT:

Forward Clutch

and Input Shaft

Replace

Repair

0.1

0.7

5,6,10,192

5,10, 21,

39,138,

159,193

Fifth Clutch Replace

Repair

0.1

0.3

5, 6, 123

5, 39

Fourth Clutch Replace

Repair

0.6

2.5

5, 6, 39

5, 10, 39

Third Clutch Replace

Repair

0.6

2.5

5, 27

5, 105

Center Support Replace

Repair

0.1

1.0

5,6,27,123

5,6,10,35,

66, 72,

101, 122

 0714 Servo Unit:

Control Valve

Assembly

Replace

Repair

*

*

5, 6

5, 6

C

C

Front Plate Assembly Replace

Repair

0.5

*

5, 6

5 C

First Shift Valve

Body Assembly

Replace

Repair

*

*

5

5, 6, 10

C

C

First Trimmer Valve

Body Assembly

Replace

Repair

0.1

0.1

5

5, 6, 10

 0721 Coolers, Pumps,

Motors:

Oil Pump Assembly Replace

Repair

*

*

5

5, 6

C

C

Low Oil Sensor

Assembly

Test

Replace

0.1

3.2

5

5, 6

08 TRANSFER, FINAL

DRIVE, PLANETARY

AND DROP GEARBOX

ASSEMBLIES

(ON VEHICLE)
TM 9-2320-364-20-5

B-15

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

0801 Power Transfer and

Final Drive Assy:

Transfer Case

Assembly

Inspect

Service

Replace

Repair

0.1

0.3

*

8.0

1, 2, 126

5, 6, 30

5, 6, 19

58, 59, 60,

61, 177

C

B

Overhaul * D

Yokes Replace 2.8 5, 6 C

Oil Seals Inspect

Replace

0.1

1.6 5

Upper Shaft Assembly Repair 1.0 5, 6, 10

Center Shaft Assembly Repair 0.5 5, 6,10, 58

Rear Shaft Assembly Repair 1.0 5, 6, 10

Differential Shaft

Assembly

Repair 1.0 5, 6, 10

Front Shaft Assembly Repair 1.0 5, 6, 10

Differential Assembly Repair 0.6 5, 6, 10,

60

0803 Gear Shift, Vacuum

Booster and Controls:

Air Chamber,

Differential

Inspect

Adjust

Replace

0.3

0.5

1.0

1

1, 2, 4

Upper Shift Rod

Assembly

Repair 1.0 5, 6, 10

Lower Shift Rod

Assembly

Repair 1.0 5, 6, 10

Shift Control Cable Adjust

Replace

0.3

2.5

1

1, 2

0804 Lubrication, Cooling,

or Hyd Components:

Lube Pump Replace

Repair

0.8

0.5

5, 6, 30

5, 6
TM 9-2320-364-20-5

B-16 

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

0804 Lubrication, Cooling,

or Hyd Components:

(CONT)

Lube Hoses (each) Inspect

Replace

0.1

0.5

1,2,4, 30

Breather Inspect

Service

Replace

0.1

0.1

0.1

1

1

09 PROPELLER,

PROPELLER

SHAFTS,

UNIVERSAL JOINTS,

COUPLER AND

CLAMP ASSEMBLY

0900 Propeller Shafts:

Propeller Shafts and

Universal Joints

Inspect

Service

Replace

Repair

0.2

0.1

0.9

0.9

1

1, 2, 4

1, 2, 4

10 FRONT AXLE

1000 Front Axle Assembly:

Axle No. 1 Assy Inspect

Service

Replace

Repair

0.1

0.6

15.2

10.0

1, 2,

5, 6, 119

5, 176

Axle No. 2 Assy Inspect

Service

Replace

Repair

0.1

0.5

11.0

10.0

1, 2,

5, 6, 119

5, 176

1002 Differential:

Axle No. 1

Differential Assembly

Replace

Repair

1.0

5.5

5, 6

5, 6, 10,

13, 19,177
TM 9-2320-364-20-5

B-17

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

1002 Differential: (CONT)

Axle No. 2 Differential

Assembly

Replace

Repair

1.5

9.8

5, 6

5, 6, 10,

13, 19,

177

Axle No.2 Rear Output

Assembly

Replace

Repair

1.0

1.0

5, 6

5

1003 Planetary or Final

Drive:

Axles No. 1 and 2

Planetary Hub Gears

Service

Replace

*

2.9 2, 5, 58

A

1004 Steering and Leaning

Wheel Mechanism:

Constant Velocity

Joint

Service

Replace

Repair

0.2

4.5

2.0

5, 6

6, 54, 55

Pivot and Spindle

Assembly

Inspect

Service

Replace

Repair

0.1

*

3.0

3.0

2, 4

5,6, 54,55,

69, 191, 

5, 6, 54

55, 191

A

11 REAR AXLE

1100 Rear Axle Assembly:

Axle No. 3 Assy Inspect

Service

Replace

0.1

0.5

8.0

1, 2

5, 6, 119

201

Axle No. 4 Assy Inspect

Service

Replace

0.1

0.5

8.0

1, 2

5, 6, 119

Axle No. 5 Assy Inspect

Service

Replace

0.1

0.5

11.0

1, 2

5, 6, 119

Axles No. 3 and 4

Spindle Assembly

Replace

Repair

3.2

*

5, 6

5, 6, 142 C
TM 9-2320-364-20-5

B-18 

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

1102 Differential:

Axle No. 3 Differential

Assembly

Replace

Repair

1.6

4.9

5, 6

5, 6, 10,

13, 19, 

51, 142, 

173, 174,

175, 176

Axle No. 4 Differential

Assembly

Replace

Repair

1.6

4.9

5, 6

5, 6, 10,

13, 19, 

177

Axle No. 5 Differential

Assembly

Replace

Repair

1.0

5.5

5, 6

5, 6, 10,

13, 19, 

177

1103 Planetary or Final

Drive:

Axles No. 3, 4 and 5

Planetary Hub Gear

Service

Replace

*

2.9 2, 5, 58

A

1104 Steering, Sideshift, and

Wheel Leaning

Mechanisms

Axle No. 5 Constant

Velocity, Pivot &

Spindle Assembly

Replace

Repair

*

*

5,6, 54,55,

69, 191

5,6,10,165

C

C

12 BRAKES

1202 Service Brakes:

Brakes Inspect 0.2 1

Brake Assemblies

(all)

Replace

Repair

1.0

7.5

5, 6 

5, 6

Brake Shoes Inspect

Adjust

Replace

0.2

0.5

1.0

1, 71

1, 4, 71

 1206 Mechanical Brake

System:

Pneumatic Brake Valve Replace

Repair

3.0

1.5

1

1, 6, 135
TM 9-2320-364-20-5

B-19

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

 1208 Air Brake System:

Air Dryer Inspect

Service

Replace

Repair

0.1

0.6

3.0

1.0

1

1, 2

1, 2, 4

Coalescing Filter/

Aftercooler

Inspect

Replace

Repair

0.1

0.7

0.1

1, 2

1, 4

 1209 Air Compressor

Assembly:

Air Compressor Inspect

Replace

Repair

0.2

3.2

4.0

5, 6, 30

5,6, 10,36,

117

Air Governor

Assembly

Adjust

Replace

0.2

1.5

1

1, 30

Air Lines Replace

Repair

*

*

1, 30

1, 4

C

C

 1211 Trailer Brake

Connections

and Controls:

Load Sensing Valve Adjust

Replace

1.0

2.0

1, 135

1, 4

13 WHEELS AND

TRACKS

 1311 Wheel Assembly:

Wheel Assembly Inspect

Replace

Repair

0.1

0.2

1.0 1, 4, 74

Wheel Hub Assembly Inspect

Service

Replace

Repair

0.2

0.1

3.4

2.1

1, 4

5, 6,169

5, 6, 50,

51, 81,139

Brake Drums

(all axles)

Inspect

Replace

Repair

0.2

1.2

*

1, 4

C
TM 9-2320-364-20-5

B-20 

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

 1311 Wheel AssemblyCONT:

Central Tire

Inflation System (CTIS)

Inspect 0.2

CTIS Controller Replace

Repair

0.2

0.1

1

1

CTIS Front

Manifold

Replace

Repair

Test

0.7

0.7

2.0

1,4,30,206

1

1

CTIS Rear

Manifold

Replace

Repair

Test

0.3

0.7

2.0

1,4,30,206

1

1

 1313 Tires, Tubes, Tire

Chains:

Tire Inspect

Replace

Repair

0.1

*

*

1 C

C

14 STEERING

 1400 Steering System Inspect

Service

Adjust

0.2

0.6

* 3.5

1, 2

1, 2, 4, 

5, 136

A

 1401 Mechanical Steering

Gear Assembly:

Steering Column Inspect

Service

Replace

0.2

*

2.2 1, 2

A

Drag Links (each) Inspect

Service

Replace

Repair

0.1

*

*

*

5, 6

5, 6, 10

A

C

C

Intergear Link Inspect

Service

Replace

Repair

0.1

*

*

*

5, 6

5, 6, 10

A

C

C

Steering Shafts Inspect

Service

Replace

0.2

*

1.5 1, 2

A
TM 9-2320-364-20-5

B-21

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

 1401 Mechanical Steering

Gear AssemblyCONT:

Tie-Rod Inspect

Service

Adjust

Replace

Repair

0.1

*

2.5

1.3

2.2

1, 2

1, 2, 4,119

1, 2, 4

A

90° Gear Box Replace

Repair

1.0

3.2

1, 2

5, 6, 10

2.21:1 Gear Reducer Service

Replace

Repair

*

0.5

0.1

5, 6

5,6,10,143

A

Axle No. 1 Align 4.0 5, 6, 26,

134

Axle No. 2 Align 4.0 5, 6, 26,

134

Axle No. 5 Align 1.0 5, 6, 26,

134

 1407 Power Steering

Gear Assembly:

Front Steering

Gear Assembly

Inspect

Service

Adjust

Replace

Repair

0.1

*

0.5

1.3

2.1

5

5,6,30,196

5, 6, 10,

143, 196

A

Intermediate Steering

Gear Assembly

Inspect

Service

Replace

Repair

0.1

*

1.0

0.7

5,6,30,196

5, 6, 10,

143, 196

A

Rear Steering

Gear Assembly

Inspect

Service

Adjust

Replace

Repair

0.1

*

0.5

1.0

2.2

5

5,6,30,196

5, 6, 10,

143, 196

A
TM 9-2320-364-20-5

B-22 

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

 1410 Hydraulic Pump or

Fluid Motor Assembly:

Emergency Steering

Hydraulic Pump,

Adjust

Replace

1.0

2.0

1

1

Emergency Steering

Hydraulic Valve

Adjust

Replace

1.0

1.5

5

5, 6, 205

 1411 Hoses, Lines, and

Fittings:

Hydraulic Lines

and Fittings

Replace * 1, 30 C

 1413 Tanks, Reservoirs:

Steering Reservoir

Assembly

Inspect

Service

Replace

Repair

0.1

*

1.2

1.3

1, 2, 4, 30,

126, 205

1, 2, 4,205

A

Steering Hydraulic

Filter

Service

Replace

*

0.2 1, 2, 4

A

Steering Hydraulic

Manifold

Replace

Repair

1.3

0.3

5, 6 ,30

5, 6

15 FRAME, TOWING

ATTACHMENTS,

DRAWBARS, AND

ARTICULATION

SYSTEMS

1501 Frame Assembly:

Cab Step Assembly Replace

Repair

0.5

0.2

1

1

Frame Assembly Inspect

Repair

0.1

5, 6, 9,205 C

1503 Pintles and Towing

Attachments:

Self-Guided Coupler Inspect

Service

Replace

Repair

0.1

0.1

1.0

1.5

1

1, 2, 4

1, 2, 4, 6
TM 9-2320-364-20-5

B-23

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

1504 Spare Wheel Carrier

and Tire Lock:

Tire Carrier and Davit Inspect

Service

Replace

0.1

*

2.3 1

A

16 SPRINGS AND

SHOCKS

ABSORBERS

1601 Springs:

Spring Hangers Inspect

Service

Replace

0.1

*

* 5

A

C

Springs Inspect

Replace

0.1

* 5, 6, 118 C

No.3 Axle Suspension

Air Bags

Inspect

Replace

0.1

1.0 5, 6

1604 Shock Absorber

Equipment:

Shock Absorber and

Bushings (each)

Inspect

Replace

0.1

0.3 1, 2

 1605 Torque, Radius, and

Stabilizer Rods:

Equalizer Beam (each) Replace

Repair

2.2

2.0

5, 6, 118

5, 93, 190

No. 3 Axle Air

Suspension

Beam Assembly

Replace

Repair

3.0

1.5

5, 6

5

No. 3 Axle Suspension

Arm

Inspect

Replace

Repair

0.1

*

3.0

5, 6

5, 6

35, 202

C

Torque Rods (each) Inspect

Replace

0.1

1.3 5, 6, 119
TM 9-2320-364-20-5

B-24 

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

18 BODY, CAB, HOOD

AND HULL

 1801 Body, Cab, Hood, and

Hull Assemblies:

Cab Assembly Inspect

Service

Replace

0.2

0.1

7.5 5,6

Cab Door Adjust

Replace

Repair

0.3

1.5

2.5

1

1

1, 4

Engine Cover

Assembly

Replace

Repair

01.

0.4

1

1

 1802 Fenders, Running

Boards with Mounting and Attaching

Parts, Windshield,

Glass, Etc.:

Windshield Glass Inspect

Replace

0.1

1.4 5

 1806 Upholstery Seats and

Carpets:

Seat Assembly Replace

Repair

Alignment

0.6

1.5

.4

1, 4

1, 4

1, 4

Sun Visor Assembly Inspect

Replace

0.1

0.3 1

1808 Stowage Racks,

Boxes, Straps,

Carrying Cases,

Cable Reels, Hose

Reels:

Ladder Support Replace

Repair

0.5

*

1, 2

1, 2

Stowage Box, Crane Replace

Repair

0.5

0.4

1, 4

1, 2, 4
TM 9-2320-364-20-5

B-25

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

20 HOIST, WINCH,

CAPSTAN,

WINDLASS,

POWER CONTROL

UNIT, AND POWER

TAKE-OFF

2001 Hoist, Capstan,

Windlass, Crane or

Winch Assembly:

Crane Assembly Inspect

Service

Test

Adjust

Replace

Repair

0.1

0.5

* *

0.5

4.0

2.0

1

1, 5,188

5, 6

5, 6, 30,

201

5, 6

A

Boom Assembly Replace

Repair

2.0

4.8

5, 6, 30

5, 6

Erection Cylinder Replace

Repair

0.6

1.5

5, 6, 30

5, 6

Lift Cylinder Assembly Replace

Repair

0.7

0.9

5, 6, 30

5, 6, 196

Tension Link

Assembly

Replace

Repair

0.2

0.5

5, 6

5, 6

Mast Assembly Replace

Repair

0.6

*

5, 6, 30

5, 6 C

Telescope Cylinder

Assembly

Replace

Repair

0.7

0.8

5, 6, 30

5, 6

Hoist Assembly Inspect

Service

Replace

Repair

0.1

0.3

1.4

1.6

1

5, 6

5, 6, 10

Hydraulic Hoist Motor Replace

Repair

0.2

5.3

5, 6, 30

5, 6

Remote Control Box Replace

Repair

0.3

1.0

1

1, 2, 4,

202
TM 9-2320-364-20-5

B-26 

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

2001 Hoist, Capstan,

Windlass Crane

or Winch Assembly -

CONT:

Crane Cable Inspect

Service

Replace

*

*

1.0 1, 4

A

A

Motor Valve

Assembly

Replace

Repair

0.1

0.4

5, 6, 30

5, 6

Hoist Brake

Assembly

Replace

Repair

0.4

1.4

5, 6, 30

5, 6

Cable Follower

Assembly

Replace

Repair

0.7

0.6

5, 6, 30

5, 6

Sub-Frame Assembly Replace

Repair

1.7

7.0

5, 6

5, 6

Swing Drive Brake Replace

Repair

2.0

1.0

5, 6

5, 6

Gear Reducer Replace

Repair

1.7

1.2

5,6,30,172

5, 6, 175

Override Solenoid

Manifold

Replace

Repair

Test

1.3

2.1

0.5

5, 6, 30

5, 6

6

Hook Block Assembly Replace

Repair

0.5

0.5

1, 2

1, 2, 4,132

Hoist Motor

Control Valves

Replace

Repair

0.5

0.1

5,6,30,201

5, 6

Hand Pump Replace

Repair

1.5

0.5

1, 2, 30

1, 2, 4,

Accumulator Service

Replace 0.2

* 1, 33

1

A

Remote Control Box

Cable Assembly

Replace

Repair

Test

0.3

0.2

0.5

1

1

2
TM 9-2320-364-20-5

B-27

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

2001 Hoist, Capstan,

Windlass Crane

or Winch Assembly -

CONT:

Self-Recovery Winch

Assembly

Inspect

Service

Replace

Repair

0.1

0.3

4.5

*

1, 2, 4, 30,

201

5, 6, 10 C

Counter Balance

Valve

Replace

Repair

0.9

0.9

5, 6, 30

5, 6, 10

Winch Brake Replace

Repair

1.0

*

4, 5

5, 6, 10 C

Front Tensioner

Assembly

Service

Replace

Repair

*

1.0

0.4

1

1, 2, 4

A

Front Cable Guide Service

Replace

*

0.1 1, 4

A

Rear Tensioner

Assembly

Service

Replace

Repair

*

1.0

0.4

1, 4

1, 2, 4

A

Rear Cable Guide Service

Replace

*

1.0 1

A

Winch Cable Inspect

Service

Replace

*

*

0.8 1, 4

A

A

Hook Machining Arm Replace

Repair

1.8

*

5, 6, 207

5, 6 C

Middle Mach Frame Replace

Repair

6.8

*

5,6,30,204

5 C

 2006 Bulldozer Tripod,

Main Frame, Jack

and Mounting:

Outrigger Cylinder Replace

Repair

1.0

4.1

5, 6, 30

5, 6

Outrigger Pad

Assembly

Replace

Repair

0.2

0.2 1, 2, 4
TM 9-2320-364-20-5

B-28 

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

22 BODY, CHASSIS,

AND HULL

ACCESSORY ITEMS

 2202 Accessory Items:

 2202 Heater Replace

Repair

1.3

3.2

1

1

Heater Blower

Motor

Replace

Repair

1.0

*

1

1, 4 C

Heater Control Panel Replace

Repair

0.8

*

1

1 C

 2210 Data Plates and

Instruction Holders:

Data Plate (each) Replace 0.2 1, 2

24 HYDRAULIC AND

FLUID SYSTEMS

 2400 Major Assemblage

(Load Handling

System):

Load Handling

System

Inspect

Service

Test

Replace

Repair

0.1

*

0.6

2.0

2.0

5, 6

5, 6, 30,

201

A

 2401 Hydraulic Pump:

Main Hydraulic

Pump Assembly

Inspect

Replace

Repair

0.2

12

19.3

5,6,30,146

5, 6, 10,

199

Pump Driveshaft Inspect

Service

Replace

Repair

*

*

1.0

0.5

1, 2

1, 2, 4

A

C
TM 9-2320-364-20-5

B-29

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

 2402 MANIFOLD AND/OR

CONTROL VALVES:

LHS Load Sensing

Valve

Replace

Test

*

0.5

1, 2 C

Multifunction

Manifold

Replace

Repair

3.0

*

5, 6

5, 6 C

 2405 Mast Column:

LHS Hook Arm

Cylinder

Service

Replace

Repair

*

1.4

2.5

5, 6, 131,

210

5,6,23,196

A

 2406 Strainers, Filters,

Lines and Fittings,

etc.:

LHS Main Manifold

Relief Valve

Adjust

Replace

Test

0.5

1.0

0.5

6

5, 6

6

LHS Main Cylinder Replace

Repair

1.1

2.5

5

5,6,23,196

Hose Assembly,

Low Pressure

Replace

Repair

1.0

*

1, 30, 126

C

High Pressure

Hydraulic Filter Head

Replace

Repair

2.0

*

1, 4

C

LHS Hook Arm

Manifold Assembly

Replace

Repair

1.6

1.6

1,201,205

LHS Main Manifold Replace

Repair

0.6

0.6

5, 6, 30

5

 2408 Liquid Tanks or

Reservoirs:

Hydraulic Reservoir

Assembly

Service

Replace

Repair

0.5

5.9

0.5

1, 2, 4, 52,

126

1, 2,4,201,

205, 207

1
TM 9-2320-364-20-5

B-30 

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

33 SPECIAL PURPOSE

KITS

 3303 Winterization Kits:

Engine Arctic Kit Inspect

Install

Replace

Repair

0.1

4.5

*

* 5, 6

1

1, 2, 4

C

C

 3307 Special Purpose Kits:

EMM Power 

Interface Kit

Replace

Repair

Install

34 ARMAMENT AND

SIGHTING AND FIRE

CONTROL

(ELECTRIC/

ELECTRONIC

MATERIAL)

 3402 Small Arms:

Machine Gun

Mounting Kit

Inspect

Replace

Install

0.1

1.0

*

1, 2

5, 6 C

47 GAGES (NONELECTRICAL)

WEIGHING AND

MEASURING

DEVICES

 4702 Gages, Mounting,

Lines, and Fittings:

Restrictor Indicator

Assembly

Inspect

Replace

0.1

0.5 1

68 RADIO TELEPHONE

SYSTEM

 6809 Radio Telephone

System

Radio Kit Replace

Install

1.0

*

1, 2

5 C
TM 9-2320-364-20-5

B-31

Section II. MAINTENANCE ALLOCATION CHART (CONT).

(1) (2) (3) (4) (5) (6)

Maintenance Level

Direct General

Group Maintenance Unit Support Support Depot Tools and

Number Component/Assembly Function C O F H D Equipment Remarks

91 CHEMICAL,

BIOLOGICAL, AND

RADIOLOGICAL

(CBR)

EQUIPMENT

 9111 Gas Particulate 

Filter Units:

Gas Particulate

Filter Unit Kit

Inspect

Install

Replace

0.2

2.2

2.0 5

1

 9131 Chemical Agent

Alarms:

Chemical Alarm Kit Inspect

Install

Replace

0.2

1.8

2.3 5, 6

1

Decontamination Kit Inspect

Install

Replace

0.2

0.5

1.0 5

1, 2
TM 9-2320-364-20-5

B-32 

Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS

Table B-1. Tool and Test Equipment Requirements 

Tool or Test

Equipment

Ref Code

Maintenance

Category Nomenclature

National/

NATO

 Stock Number

Tool 

Number

1 O TOOL KIT, General Mechanic’s:

 Automotive 5180-00-177-7033 SC 5180-90-N26

2 O SHOP EQUIPMENT, Automotive

 Maint and Repair: Common No. 1 4910-00-754-0654 SC 4910-95-A74

3 O SHOP EQUIPMENT, Automotive

 Maintenance and Repair: Supp. 1 4910-00-754-0653 SC 4910-95-A73

4 O SHOP EQUIPMENT, Automotive

 Maint and Repair: Common No. 2 4910-00-754-0650 SC 4910-95-

A72-HR

5 F TOOL KIT, General Mechanic’s 5180-00-699-5273 SC 5180-90-

N05-HR

6 F SHOP EQUIPMENT, Automotive

 Maintenance and Repair:

 Field Maintenance, Basic 4910-00-754-0705 SC 4910-95-A31

7 F SHOP EQUIPMENT, Automotive

 Maintenance and Repair:

 Field Maintenance 4910-00-754-0706 SC 4910-95-A62

8 F SHOP EQUIPMENT, Fuel and

 Electrical System, Engine:

 Field Maintenance, Basic 4940-00-754-0714 SC 4940-95-

B20-HR

9 F SHOP WELDING SET 3433-00-357-6311 SC 3433-90-

N01-HR

10 H SHOP EQUIPMENT, Automotive

 Maintenance and Repair:

 Field Maintenance, Supp. 2 4910-00-754-0707 SC 4910-95-A63

11 F SHOP EQUIPMENT, Machine Shop 3470-00-754-0708 SC 3470-95-A02

12 H ADAPTER, Engine Stand 4910-00-146-9624 J33850

13 H ADAPTER, Maintenance Stand,

Differential 4910-01-384-6264 J-39929-A

14 F ADAPTER, Mechanical Puller 5120-00-733-8890 J7932

15 F ADAPTER, Quick Disconnect 5935-01-297-2481 J33765

16 O ADAPTER, Radiator 4910-01-170-4929 J29003-A

17 F ADAPTER, Socket (3/4 in. Female to

 1/2 in. Male) 5120-00-227-8088 97-3725

18 F ADAPTER, Socket (3/4 in. Female to

 1 in. Male) 5120-00-227-8104 A-A-2172

19 H ADAPTER KIT, Transfer Case 4910-01-385-6779 J-39911

20 F ALIGNMENT TOOL, Blower 5120-01-158-3991 J33001
TM 9-2320-364-20-5

B-33

Table B-1. Tool and Test Equipment Requirements (Cont).

Tool or Test

Equipment

Ref Code

Tool 

Number

National/

NATO

Nomenclature Stock Number

Maintenance

Category

21 H ALIGNMENT TOOL, Clutch 5120-01-115-1156 J24221

22 H ALIGNMENT TOOL, Pin 5120-01-232-0007 J24285

23 O ANALYZER SET, STE/ICE-R 1910-01-222-6589 12259266

24 H ATTMENT, BALL, MICRO 5120-00-221-1921 J4757

25 H BRACKET, Lifting 5306-01-338-6292 J24408-A

26 F BOX, Chalk, Reel and Line 5210-00-273-9793 GGG-C-291

27 H BRACKET, Lifting 5120-01-115-1157 J24196

28 H BRACKET, Mounting, Cylinder Liner 5340-01-158-3984 J24565-02

29 H BRUSH, Wire, Valve Cylinder 5120-00-766-2141 J5437

30 O CAP AND PLUG SET 5340-00-450-5718 10935405

31 O CARTRIDGE, DDEC 7030-01-354-6174 J38500-750

32 O CARTRIDGE, ATEC 4940-01-367-6194 J38500-300

33 F CHARGING KIT, Pressure 4910-01-046-7109 12252157

34 F COMPRESSOR, Air Unit 4130-00-752-9633 MIL-C-13874

35 H COMPRESSOR SET, Snap Ring 5120-01-116-5016 J24208-D

36 H COMPRESSOR, Ring 5120-01-048-3129 J24204-1

37 H COMPRESSOR, Ring 4910-01-158-3974 J24227

38 F COMPRESSOR, Ring, Piston 5120-00-250-6055 RC40C

39 H COMPRESSOR, Seal 5120-01-048-2159 J24204-3

40 F COMPRESSOR, Spring Valve 5120-01-297-2397 J7455-A

41 H COMPRESSOR, Spring 5120-01-048-2160 J24219

42 O CONNECTOR REMOVER 5120-01-355-3012 J38384

43 O CONNECTOR REMOVER

 Electrical Contact 5120-01-158-4707 114010

44 O CRIMPING TOOL 5120-01-355-0844 J35123

45 O CRIMPING TOOL (CANNON) 995-0001-904

46 H DETECTOR, Leak, Vacuum Gage 6685-01-061-4253 J23987-B

47 F DRILL MACHINE, Upright 3413-00-165-4117 MIL-D-80038

48 F DRIVER 5120-01-374-6200 2HE496

49 H DRIVER BEARING, Gear 5120-01-033-8902 J25257

50 F DRIVER, CTIS Seal 5120-01-355-0857 J41112

51 F DRIVER, CTIS Seal 5120-01-355-0858 J41113

52 O DRUM, Storage 57 gal 8110-00-082-2626 MIL-D-6054

53 F EXPANDER, Seal, Oil 5120-00-336-0445 J4239

54 F EXTRACTOR, Inertial 2HE226
TM 9-2320-364-20-5

B-34 

Table B-1. Tool and Test Equipment Requirements (Cont).

Tool or Test

Equipment

Ref Code

Tool 

Number

National/

NATO

Nomenclature Stock Number

Maintenance

Category

55 F EXTRACTOR, Inertial 5120-01-354-9543 2HE227

56 O EXTRACTOR TOOL, Elect 5120-01-015-2154 91019-3

57 O EXTRACTOR TOOL, Elect 5120-00-020-5926 305183R

58 F EYES, Lifting 5306-01-197-6569 3016T39

59 F EYES, Lifting 5306-01-333-5486 8891T82

60 F EYES, Lifting 5306-01-239-5053 3016T65

61 H FIXTURE, Holding 5120-01-115-1165 J24310

62 F FIXTURE, Lifting, Cylinder Head 4910-00-456-7620 J22062-01

63 H FIXTURE, PTO, Gear 4910-01-158-3969 J26899

64 H FIXTURE, Test, Head 4910-01-158-3985 J28454

65 O GAGE, Belt Tension 4935-01-254-9808 BT-33-73-BF

66 H GAGE, Center and Front 5210-01-133-6888 J29198-3

67 H GAGE, Cylinder, Bore 5210-01-070-4543 J5347-B

68 H GAGE, Depth Cylinder, Liner 5210-01-174-4498 J24898

69 F GAGE, Depth 5210-00-023-4798 J22273-01

70 F GAGE, Dial 5120-00-494-1846 J-8165-2

71 O GAGE, Feeler, Jacobs Brake 5210-01-214-2138 007958

72 F GAGE, Feeler 5120-00-671-2275 J3174-02

73 H GAGE, Groove 5220-01-028-1109 J24599

74 O GAGE, Inflation 4910-00-204-2644 100708

75 F GAGE Set, Feeler 5210-01-119-7601 FB310B

76 F GAGE Set, Feeler 5210-01-245-9564 J1698-02

77 F GAGE Set, Feeler, Piston 5210-00-416-1631 J5438-01

78 F GAGE, Timing, Injector 5220-01-348-1638 J25502

79 F GAGE, Valve, Adjustable 5220-00-176-0638 J9708-15

80 F HAMMER, Slide 5120-01-112-2165 J6125-16

81 F HANDLE, Driver 5120-00-677-2259 J8092

82 H HANDLE, Driver 5120-00-808-5082 J3154-1

83 H HANDLE, Driver 5120-01-054-4048 J24202-4

84 O HANDLE, Installer 5120-00-977-5578 J7079-2

85 O HARNESS, Breakout 6150-01-373-7771 J34517

86 F HOLDER, Stator, Roller 5120-01-115-1158 J24218-2

87 H HONING UNIT 5130-00-629-9782 J5902-01

88 F INDICATOR, Dial, Timing Tool 2815-01-355-6628 J34930-A
TM 9-2320-364-20-5

B-35

Table B-1. Tool and Test Equipment Requirements (Cont).

Tool or Test

Equipment

Ref Code

Tool 

Number

National/

NATO

Nomenclature Stock Number

Maintenance

Category

89 F INDICATOR, Dial 5120-00-402-9619 J7872

90 H INDICATOR, Dial, Set 5120-00-794-9178 J5959-01

91 F RECONDITIONING SET

 Injector, Tube 5180-00-146-9619 J22525-B

92 F INSERTER AND REMOVER 5120-01-166-0572 J33080

93 H INSERTER, Bearing and

 Bushing 5120-01-158-3946 J25562

94 H INSERTER, PLUG, Cylinder Block 5120-01-166-5419 J21850

95 H INSERTER, SEAL 5120-01-340-1820 J35373

96 O INSERTION TOOL (CANNON) 5120-01-374-8968 CIT-SS-10

97 H INSTALLER AND REMOVER 5120-01-048-2180 J25275

98 H INSTALLATION TOOL, Cup Plug 5120-01-297-2457 J33420

99 H INSTALLER, Bearing 5120-01-115-1160 J24197

100 F INSTALLER, Guide, Valve 5120-00-999-8617 J21520

101 H INSTALLER, Lock Ring 5120-01-054-4050 J24453

102 F INSTALLER, Oil Seal 5120-01-227-8483 J21983

103 H INSTALLER, Output Shaft 5120-01-054-4042 J24202-1A

104 H INSTALLER, Plug 5120-01-385-7288 J24411

105 H INSTALLER, Plug 5120-01-054-4053 J24369

106 F INSTALLER, Seal 5120-01-054-4049 J24198

107 F INSTALLER, Seal, Crankshaft, Front 5120-00-936-4377 J9783

108 F INSTALLER, Seal 5120-01-013-1678 J9791

109 O INSTALLER, Seal 5120-00-977-5579 J8550

110 F INSTALLER, Seal, Flywheel 4910-01-176-4230 J21112-B

111 H INSTALLER, Seal, Oil 5120-00-937-7267 J8501

112 H INSTALLER, Seal, Transfer Case 5120-01-383-7878 TRS6227

113 H INSTALLER, Valve Bridge 5120-00-999-8616 J7482

114 H INSTALLER, Water Pump Seal 5120-01-365-4079 J-38858

115 H INSTALLING TOOL, Piston 5120-00-127-7757 J23762-A

116 H INSTALLING TOOL, Valve 5120-01-048-3118 J24357

117 H INSTALLING/REMOVING Tool 5120-01-130-8864 J23019

118 F JACK, Stabilizer 2590-00-23-7418 10876244

119 O JACK KIT, Hydraulic, Hand 5120-00-587-4144 GGG-J-60

120 F LEVEL 4920-00-064-8974 2579573-002

121 F LIFTING BRACKET, Flywheel 5120-01-116-6049 J24365
TM 9-2320-364-20-5

B-36 

Table B-1. Tool and Test Equipment Requirements (Cont).

Tool or Test

Equipment

Ref Code

Tool 

Number

National/

NATO

Nomenclature Stock Number

Maintenance

Category

122 H LIFTING Bracket, Center 5120-01-116-6048 J24195

123 H LIFTING Fixture, Clutch 5120-01-115-1159 J24209

124 H MAG INS. UNIT, Stat 6635-00-566-9772 MIL-M-6867C

125 F OIL, Seal, Expander 5120-01-232-0005 J8682

126 O PAN, DRAIN 6 Gal 4910-00-287-2944 MIL-P-45819

127 F PIN, Guide Set 5120-01-115-1163 J24315

128 F STUDS, Guide 5315-01-162-3630 J24748

129 H PIN, GUIDE 5315-01-165-1469 J1126

130 H PLATE KIT, Gear Bearing 5180-01-167-4285 2SK900

131 F PLIERS, Channel Lock 5120-00-287-2512 GGG-W-649

132 O PLIERS, Retaining Ring 5120-01-375-5699 2BH945

133 F PLUG, Cylinder Block 5120-01-166-5421 J24597

134 F PLUMB BOB 5210-00-007-8229 GGG-P-501

135 O PRESSURE TEST KIT 4910-01-378-9068 3SK911

136 F PRESSURE TEST KIT 4910-01-378-8863 3SK912

137 H PROTECTOR, Piston 5120-01-048-2156 J24210

138 H PROTECTOR, Seal 5120-01-048-2157 J24216-01

139 F PROTECTOR, Spindle 3830-01-349-7390 2HE234

140 F PROTRACTOR, Magnetic 5210-01-415-0075 2150A251

141 F PROTRACTOR, Square 5210-00-273-1937 05-12INCH

142 F PULLER, Bolts 5120-01-185-6811 J26901-A

143 H PULLER, Mech 5120-00-219-8397 J1902-B

144 F PULLEY REMOVER 5120-00-944-0363 J5356

145 F PUMP, FORCE 4130-01-192-0496 466-46485

146 O PULLEY KIT, Pump, Roof Mount 5120-01-375-5700 2HP645

147 F PUNCH, DRIFT 5120-00-004-4921 PWA14920

148 O READER, Diagnostic (DDEC) 4910-01-343-3508 J38500-1

149 H REMOVER, Bearing, Front Support 5120-01-117-2523 J28557

150 H REMOVER, Snap Ring 4910-01-158-3996 J26598-A

151 H REMOVER, Valve Bridge 5120-00-999-8615 J7453

152 H REMOVER, Valve Pin 5120-01-048-3128 J-24412-2

153 H REMOVER, Valve Seat 5120-01-165-1935 J23479-E

154 F REMOVER AND INSTALLER,

 Piston Ring 5120-00-494-1846 7950177
TM 9-2320-364-20-5

B-37

Table B-1. Tool and Test Equipment Requirements (Cont).

Tool or Test

Equipment

Ref Code

Tool 

Number

National/

NATO

Nomenclature Stock Number

Maintenance

Category

155 F REMOVER ASSEMBLY 4910-01-158-3982 J24563-A

156 H REMOVER SET, Valve Bridge 5120-00-999-8614 J7091-01

157 H REMOVER, Guide Valve 5120-00-733-8880 J6569

158 H REMOVER, Seal, Waterpump 4910-01-158-3979 J22150-B

159 H COLLECTOR RING,

 Installer/Stalking SET 5120-01-048-3126 J24200

160 F RIVET GUN 5130-00-982-8078 352

161 F RULE, STEEL, Machinist 5120-00-204-1283 GGG-R-791

162 F SCALE, TENSION 4910-00-779-6832 J-8129

163 F SCREW, Guide 5120-01-144-4483 J1927-01

164 H SLEEVE, Puller 4910-01-162-3633 J25007-4

165 H SOCKET, 1-11/16 in. 5120-01-024-0168 GGG-W-641

166 H SOCKET WRENCH Attachment,

 Screwdriver 5120-01-297-2374 J34650

167 H SOCKET, 55mm 5120-01-386-5999 J39938

168 H SOCKET, 63mm 5120-01-386-5988 J39939

169 F SOCKET, Spindle Nut 5120-01-354-9451 J41111

170 H SOCKET, Socket Head Screw 4470-01-350-0895 LAW124A

171 H SOCKET, 12mm Hex Head 5120-00-240-6148 849550-3-8AF

172 F SOCKET, Swivel 13/16 in. 5120-00-236-7619 A-A-1396

173 H SPANNER 5120-01-354-9452 12379639

174 H SPANNER 5120-01-354-9450 12379638

175 H SPANNER 5120-01-354-9449 12379637

176 H STAND, Maintenance, Axle 4910-00-241-3329 150-AX

177 H STAND, Maintenance, Engine 4910-00-808-3372 J29109

178 H STEAM CLEANER 7910-01-157-8272 PRO 12-5

179 H STONE, Abrasive Cylinder 5130-00-937-7280 J5902-14

180 H STONE, Sharpening 5345-00-584-4607 A6F0

181 H STUD SET 5120-01-048-2155 J25002

182 F TAP AND DIE SET 5136-01-119-0005 TDM99117

183 O TERMINAL CRIMPER 5120-01-355-0845 J35688

184 O TERMINAL REMOVER 5120-01-357-2937 J35689-A

185 O TERMINAL REMOVER 5120-01-353-2534 J33095

186 O TESTER, Pressure, Radiator 4910-01-170-4928 J24460-01

187 H TESTING KIT, Cylinder 5180-01-252-9800 2SK737
TM 9-2320-364-20-5

B-38 

Table B-1. Tool and Test Equipment Requirements (Cont).

Tool or Test

Equipment

Ref Code

Tool 

Number

National/

NATO

Nomenclature Stock Number

Maintenance

Category

188 F OSS TESTER 4910-01-370-4908 13189

189 H TOOL SET, Blower 4940-00-611-7945 J6270-G

190 F TOOL SET, Equalizer Beam 4940-01-386-6108 1764

191 F TOOL, Knuckle, Adjusting 5120-01-355-6571 J41115

192 H TOOL, Lifting 5120-01-159-1736 J33079-1

193 H TOOL, Staking 5120-01-359-2757 J24200-1

194 O TOOL, SRS/TRS Alignment 5120-01-343-1001 J39815

195 F TORCH, Propane 3433-01-161-4998 737-1-0000

196 F VISE, Pipe, Chain 5120-00-078-6662 CV12

197 O WEATHERPAC CRIMPER 5120-01-374-8936 J38852

198 O WEATHER TERMINAL

 REMOVER 5120-01-374-8969 J36400-5

199 F WINCH, Cable, Hand Operating 3950-00-079-1202 415526-1

200 F WRENCH, Chain 5120-01-192-9403 CW24

201 O WRENCH, Combination 1 5/8 in. 5120-01-016-7144 1180

202 O WRENCH, Combination 1 11/16 in. 5120-00-184-8566 A-A-1351

203 O WRENCH, Combination 1 3/4 in. 5120-00-020-8658 1256

204 F WRENCH, Combination 1 13/16 in. 5120-00-081-9099 GGG-W-636

205 O WRENCH, Combination 1 7/8 in. 5120-00-020-8632 1260

206 O WRENCH, Combination 2 in.

207 O WRENCH, Combination 2 1/8 in. 5120-00-203-4795 1268

208 O WRENCH, Fuel Line 5120-00-019-5232 J-8932-B

209 F WRENCH SET, Pushrod 5120-00-132-2109 J21100-D

210 H WRENCH, Spanner 5120-01-375-4502 J41108
TM 9-2320-364-20-5

B-39/(B-40 blank)

Section IV. REMARKS

REFERENCE

CODE REMARK

A No specific times established. Times required for inspection, service, or test will depend on

extent of testing required.

B This task covers the entire on-stand repair. Use tools listed in the individual tasks for those

tasks.

C No specific times established. Times required for replacement or repair will depend on extent of

work required.

D No specific times established. Times required for overhaul will depend on extent of work

required.

E In the “O” category repair is limited to splicing of wires, taping of the harness or wires, and the

replacement of wire ends.

F At the “F” level the entire wire harnes is replaced.

G Repair consists of replacing individual items.

H High pressure hoses are non-repairable.

I Repair of the gas particulate filter is covered in TM-(TBD).

J Repair of the M-8 chemical alarm is covered in TM 3-6665-225-12.

K Repair of the M-13 decontamination unit is covered in TM 3-4230-214-12&P.

TM 9-2320-364-20-5

C-1

APPENDIX C

EXPENDABLE SUPPLIES AND MATERIALS LIST

Section I. INTRODUCTION.

C-1. SCOPE.

This appendix lists expendable supplies and materials you will need to operate and maintain the PLS. These items are

authorized to you by CTA50-970, Expendable Items (Except Medical, Class V, Repair parts and Heraldic Items) or

CTA8-100, Army Medical Department Expendable/Durable Items.

C-2. EXPLANATION OF COLUMNS.

a. Column (1) - Item Number. This number is assigned to the entry in the listing and is referenced in the

narrative task box to identify the material (e.g., “Compound, Cleaning, Item 5, Appendix C”).

b. Column (2) - Level. This is the maintenance level approved to use the item listed.

c. Column (3) - National Stock Number. This is the National Stock Number assigned to the item; use it

to request or requisitely the item.

d. Column (4) - Description. Indicates the Federal item name and, if required, a description to identify the

item. The last line for each item indicates the Commercial and Government Entity (CAGE) code in parentheses

followed by the part number.

e. Column (5) - Unit of Measure. Indicates the measure used in performing the actual maintenance

function. This measure is expressed by a two-character alphabetical abbreviation (e.g., ea, in. or pr). If the unit

of measure differs from the unit of issue, requisition the lowest unit of issue that will satisfy your requirements.
TM 9-2320-364-20-5

C-2 

Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST 

(1)

Item

Number

(2)

Level

(3)

National Stock

Number

(4)

Description

(5)

U/M

1 O Adhesive

(45152) 1490170

 Sikaflex 221 gray gl

2 O

8040-01-321-1254

Adhesive

(05972) Loctite #409

 20 gram tube gm

3 O

8040-01-033-7507

8040-00-691-6134

Adhesive

(04963) EC847

 5 ounce tube

 1 gallon can

oz

gl

4 O

8040-01-046-5061

Adhesive

(05972) Loctite #44581

 4 gram kit gm

5 O

8040-00-148-7182

Adhesive

(04963) 1300

 5 ounce tube oz

6 O

8040-00-851-0211

8040-00-865-8991

8040-01-331-7470

Adhesive

(71984) RTV 732 Black

 5 oz kit

 12 oz kit

(80244) MIL-A-46106 Group 1 Type 1

 5 oz tube

oz

oz

oz

7 O

8040-00-701-9546

8040-01-010-8758

8040-01-331-7469

8040-01-331-7475

Adhesive

(71984) RTV 732 Clear

 5 oz kit

 12 oz kit

(80244) MIL-A-46106 Group 1 Type 1

 3 oz tube

 12 oz cartridge

oz

oz

oz

oz

8 O

8040-01-260-1939

Adhesive

(71984) RTV 738

 5 oz tube oz

9 O

8040-00-118-2695

Adhesive

(01139) RTV-162

(71984) Silastic 738 RTV

(81349) MIL-A-46146

 3 oz kit oz

10 O

8040-00-843-0802

8040-01-173-9815

Adhesive

(01139) RTV 108

 3 ounce kit

 12 ounce tube

oz

oz

11 O

8040-00-390-7959

Adhesive

(18876) 13086263

 1 quart can qt
TM 9-2320-364-20-5

C-3

Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST (Cont)

(1)

Item

Number

(5)

U/M

(4)

Description

(3)

National Stock

Number

(2)

Level

12 O Adhesive, Insulation

(28112) 4289

 5 gallon can gl

13 O

8030-01-303-0502

Adhesive, Retaining

(05972) 68035

 50 ml bottle bt

14 O Adhesive Sealant

(45152) 24758FX oz

15 O Adhesive, (0PMN0) Sika 255 FC Blk

(45152) 3145938 oz

16 O Adhesive Spray

(45152) 1537350 oz

17 O

6810-01-075-5546

Alcohol, Isopropyl

(53390) 7618-19-4

 40 oz bottle oz

18 O

6850-00-174-1806

Antifreeze

(81349) MIL-A-11755

 55 gallon drum gl

19 O

6850-00-181-7929

6850-00-181-7940

Antifreeze (81349) MIL-A-46153

 1 gallon bottle

 55 gallon drum

gl

gl

20 O

8030-00-155-6444

Antiseize Compound

(81349) MIL-A-907

 16 oz aerosol can oz

21 O

8030-00-251-3980

Antiseize Compound

(81349) MIL-A-907

 1 lb can lb

22 O

8030-00-597-5367

Antiseize Compound, High Temperature

(81349) MIL-A-907

2-1/2 lb can lb

23 O

8020-00-178-8305

Brush, Paint

(96906) MS16866 ea

24 O

6840-00-300-6373

6840-01-173-6940

Biocide, Fuel Preservative

(OU7J1) Biobar J.F.

 1 quart

 5 gallon

qt

gl

25 O

5975-01-273-8133

Cable Ties

(96906) MS3367-3

 12 inches long, 100 per package hd

26 O

5975-00-074-2072

Cable Ties

(96906) MS3367-1

 6 inches long, 100 per package hd
TM 9-2320-364-20-5

C-4 

Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST (Cont)

(1)

Item

Number

(5)

U/M

(4)

Description

(3)

National Stock

Number

(2)

Level

27 O

4310-01-115-2297

Cable Ties

(56501) TY525MX ea

28 O

7510-00-537-6426

Chalk, Marking, White

(83030) 1400 ea

29 O

9150-01-079-6124

Cleaner, Lubricant A

(81349) MIL-L-63460

 4 oz bottle, w/extender tube oz

30 O

5350-00-221-0872

Cloth, Abrasive (Crocus)

(58536) A-A-1206

 50 sheet package sh

31 O

7920-00-165-7195

7920-00-044-9281

Cloth, Cleaning

(81349) MIL-C-85043

 Type 1 - 10 lb box

 Type 2 - 10 lb box

lb

lb

32 O

8030-00-546-8621

Coating Compound, Bituminous, Solvent Type

(70842) 765-1505

 21 ounce aerosol can oz

33 O

8030-00-231-2349

8030-00-231-2344

8030-00-174-3242

Coating, Rust Arresting

(81349) MIL-R-10036

 1 gallon can

 5 gallon can

 55 gallon drum

gl

gl

gl

34 O

8030-00-062-6950

8030-01-149-1731

8030-00-837-6557

8030-00-903-0931

Corrosion Preventive Compound

(81349) MIL-C-16173

 Grade 1 - 1 quart can

 Grade 2 - 1 quart can

 Grade 3 - 1 pint can

 Grade 4 - 1 pint can

qt

qt

pt

pt

35 O Corrosion Preventive Compound

(13548) 97940

 8 ounce can oz

36 O

8030-00-231-2353

8030-00-285-1570

Corrosion Preventive Compound

(81349) MIL-C-11796

 5 lb

 35 lb

lb

lb

37 O

8010-00-652-3626

Dye, Prussian Blue

(81349) MIL-P-30501 oz

38 O

8040-00-092-2816

Epoxy

(96900) 04001 ea

39 O

5330-01-325-6993

Gasket, Forming Compound

(0597) Loctite #515

 50 ml tube ml
TM 9-2320-364-20-5

C-5

Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST (Cont)

(1)

Item

Number

(5)

U/M

(4)

Description

(3)

National Stock

Number

(2)

Level

40 O Gasket, Strip

(45152) 2011160

 50 ft. roll in

41

9150-01-197-7688

9150-01-197-7690

9150-01-197-7689

Grease

(45152) 1864450

 2.25 oz tube

 1.75 lb can

 6.5 lb can

oz

lb

lb

42 O

9150-01-197-7688

9150-01-197-7690

9150-01-197-7689

Grease, Automotive And Artillery

(70878) 5542P

(81349) MIL-G-10924

 2.25 oz tube

 1.75 lb can

 6.5 lb can

oz

lb

lb

43 O

9150-01-306-9202

9150-00-235-5555

9150-00-823-8047

Grease, General Purpose

(81349) MIL-G-23549

 1 pound can

 6.5 pound can

 35 pound can

lb

lb

lb

44 O

9150-01-154-1259

Grease, High Temperature

(81349) DOD-G-85733 qt

45 O

9150-01-235-5057

Grease, Instrument

(97343) SRI2

 1 pint can pt

46 O

9150-00-076-1887

Grease, Lubriplate

(73219) 06706 oz

47 O

9150-01-091-9336

9150-00-754-2595

9150-00-223-4004

9150-00-965-2003

Grease, Molybdenum Disulfide

(58372) 60G

 1.5 lb can

(81349) MIL-G-21164

 1.75 lb can

 6.5 lb can

 35 lb can

lb

lb

lb

lb

48 O Heatshrink, Sealed

(45152) 1704950 ea

49 O Hot Melt

(04963) 3783 oz

50 O

9150-00-189-6727

9150-01-177-3988

9150-00-191-2772

9150-00-183-7807

Hydraulic Oil, OE/HDO 10

(81349) MIL-L-2104

 1 quart can

 12 quart box

 55 gallon drum

 Bulk

qt

qt

gl

gl
TM 9-2320-364-20-5

C-6 

Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST (Cont)

(1)

Item

Number

(5)

U/M

(4)

Description

(3)

National Stock

Number

(2)

Level

51 O

6850-00-779-6851

Injector Test Oil

(33287) J-26400-5 oz

52 O Insulation, Cab

(40501) MC5150-1/2 blk ft

53 O

2540-00-256-5529

2540-00-256-5526

2540-00-256-5527

Lubricant, Tire

(96980) AA20

 5 gallon can

 1 quart can

(96980) AA17

 1 gallon can

gl

qt

gl

54 O

9250-00-186-6681

9150-00-188-9858

9150-00-189-6729

Lubricating Oil, Engine OE/HDO 30

(81349) MIL-L-2104

 1 quart can

 5 gallon can

 55 gallon drum

qt

gl

gl

55 O

9150-00-189-6730

9150-00-188-9862

9150-00-405-2987

Lubricating Oil, Engine OE/HDO 40

(81349) MIL-L-2104

 1 quart can

 55 gallon drum

 Bulk

qt

gl

gl

56 O

9150-01-152-4117

9150-01-178-4725

9150-01-152-4118

9150-01-152-4119

Lubricating Oil, Engine OE/HDO 15W/40

(81349) MIL-L-2104

 1 quart can

 12 quart box

 5 gallon can

 55 gallon drum

qt

qt

gl

gl

57 O

9150-00-402-4478

9150-00-402-2372

9150-00-491-7197

Lubricating Oil, Engine OEA

(81349) MIL-L-46167

 1 quart can

 5 gallon can

 55 gallon can

qt

gl

gl

58 O

9150-01-035-5390

9150-01-048-4593

9150-01-035-5391

Lubricating Oil, Gear GO 75W

(81349) MIL-L-2105

 1 quart can

 1 gallon can

 5 gallon can

qt

gl

gl

59 O

9150-01-035-5392

9150-01-313-2191

9150-00-001-9395

Lubricating Oil, Gear GO 80W/90

(81349) MIL-L-2105

 1 quart can

 1 gallon can

 5 gallon can

qt

gl

gl
TM 9-2320-364-20-5

C-7

Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST (Cont)

(1)

Item

Number

(5)

U/M

(4)

Description

(3)

National Stock

Number

(2)

Level

60 O

9150-01-293-7696

9150-01-293-2792

Lubricating Oil, Preservative

(15W40) (Engine)

(81349) MIL-L-21260C

 5 gallon

 55 gallon

gl

gl

61 C

9140-00-286-5286

Oil, Fuel, Diesel Winter

 Bulk gl

62 C

9140-00-286-5294

Oil, Fuel, Diesel Regular

 Bulk

gl

63 O

9150-00-250-0931

9150-00-250-0926

9150-00-250-0933

Petrolatum, Technical

(81348) VV-P-236

 8 ounce tube

 1.75 pound can

 7.5 pound can

oz

lb

lb

64 O Primer, (0PMN0) Sika Cleaner 205

(45152) 3145939

oz

65 O

8030-01-388-5604

Primer, “T” 7471

(05972) 19267

oz

66 O Protective Coating

(45152) 1412020

 1 quart can qt

67 O

7920-00-205-1711

Rags, Wiping

(58536) A-A-531

 50 pound bale lb

68 O Sealant, Electrical

(00CE9) RTV200-257

69 O Sealant, Metal

(45152) 1317520)

70 O Sealant, Rubber

(45152) 1494320

71 O

1015-01-255-4144

Sealant, Teflon Pipe

(19207) 12297953

 50 ml tube ml

72 O

8030-01-054-0740

8030-00-204-9149

8030-01-166-0675

Sealing Compound

(05972) Loctite #567

 50 ml bottle

 250 ml tube

(05972) Loctite #567-47

 50 ml tube

ml

ml

ml
TM 9-2320-364-20-5

C-8 

Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST (Cont)

(1)

Item

Number

(5)

U/M

(4)

Description

(3)

National Stock

Number

(2)

Level

73 O

8030-00-111-2763

8030-00-111-2762

8030-01-050-8288

Sealing Compound

(05972) Loctite #290

(80244) MIL-S-46163 Type 3 Grade R

 10 ml bottle

 50 ml bottle

 150 ml bottle

ml

ml

ml

74 O

8030-00-148-9833

8030-01-158-6070

Sealing Compound

(05972) Loctite #271

(80244) MIL-S-46163 Type 1 Grade K

 10 ml bottle

 50 ml bottle

ml

ml

75 O

8030-00-656-1426

Sealing Compound

(77247) Permatex-3D

(80244) MIL-S-45180 Type 3

 1 pint can pt

76 O

8030-01-159-4374

8030-01-142-9830

8030-01-142-3131

Sealing Compound 

(05972) Loctite #262

 10 ml bottle

 50 ml bottle

 250 ml bottle

ml

ml

ml

77 O

8030-01-104-5392

8030-01-014-5869

8030-01-025-1692

Sealing Compound

(05972) Loctite #242

(80244) MIL-S-46163A Type 2 Grade N

 10 ml bottle

 50 ml bottle

 250 ml bottle

ml

ml

ml

78 O

8030-01-054-3968

8030-01-069-3046

8030-01-055-6126

Sealing Compound

(05972) Loctite 222

(80244) MIL-S-46163A Type II Grade M

 10 ml bottle

 50 ml bottle

 250 ml bottle

ml

ml

ml

79

8030-01-303-0502

8030-01-387-2007

Sealing Compound

(05972) Loctite #680

 50 ml bottle

 250 ml bottle

ml

ml

80 O

8030-01-023-4535

Sealing Compound

(04963) 3M2084 oz

81 O

8030-00-954-9371

Sealing Compound

(77247) 51D

 1 pint can pt
TM 9-2320-364-20-5

C-9

Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST (Cont)

(1)

Item

Number

(5)

U/M

(4)

Description

(3)

National Stock

Number

(2)

Level

82 O

8030-01-104-5392

8030-01-014-5869

8030-01-025-1692

Sealing Compound

(45152) 079-820400

 10 ml bottle

 50 ml bottle

 250 ml bottle

ml

ml

ml

83 O

8030-01-104-5392

8030-01-014-5869

8030-01-025-1692

Sealing Compound

(45152) 65270AX

 10 ml bottle

 50 ml bottle

 250 ml bottle

ml

ml

ml

84 O

6850-00-294-0860

Silicone Compound

(72984) DC 111

 5 ounce Tube oz

85 O

6850-00-177-5094

Silicone Compound, Anti-Corrosion

(71984) DC4-2OZ

 2 ounce tube oz

86 O

6810-00-252-1345

Solution, Soap

(81349) MIL-W-15000 Class C

 1 quart bottle qt

87 O

6850-00-664-5685

6850-00-264-9038

6850-01-378-0679

Solvent, Drycleaning

(58536) A-A-711

(81348) P-D-680

 1 quart can

 5 gallon can

(Environmentally Compliant Solvent)

(0K209) Breakthrough

 5 gallon can

qt

gl

gl

88 O

9905-00-720-3577

Tag, Identification

(16956) 12-105

 white ea

89 O

9905-00-537-8957

9905-00-537-8955

Tags, Identification

(81349) MIL-T-12755

 white

 yellow

ea

ea

90 O

7510-00-079-7604

Tape, Adhesive

(26066) 4516

 36 yard roll yd

91 O Tape, Foam

 36 yard roll yd

92 O

5330-01-084-5058

Tape, Foam

(45152) 107685A in
TM 9-2320-364-20-5

C-10 

Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST (Cont)

(1)

Item

Number

(5)

U/M

(4)

Description

(3)

National Stock

Number

(2)

Level

93 O

8030-00-889-3535

Tape, Antiseizing

(81755) P5025-2R

(81349) MIL-T-27730

 260 inch spool in

94 O

7510-01-358-8770

Tape, Pressure Sensitive

(52152) 4950 36 yard roll yd

95 O Vapor Corrosion Inhibitor

(44695) VCI 326

(81349) MIL-P-46002B

 1 pint pt

96 O Vapor Corrosion Inhibitor

(44695) VCI 329

(81349) MIL-P-46002B

 1 pint pt

97 O

8010-00-401-0421

Varnish

(79819) FIXATIF

 1 quart can qt

98 C

6850-00-926-2275

Washer Fluid

(81348) O-C-1901

 1 gallon bottle gl

99 O

6145-01-074-7535

Wire, 16 Gage

(45152) 1927FX ft

100 O

9505-00-331-3275

Wire, Safety

(96906) MS20995C41 lb

101 O

5330-01-325-6993

Wrench, Loctite #515

(05972) 25824AX ml
TM 9-2320-364-20-5

D-1

APPENDIX D

ILLUSTRATED LIST OF MANUFACTURED ITEMS

Section I. INTRODUCTION

D-1. SCOPE.

This appendix includes complete instructions for manufacturing or fabricating authorized items locally. All bulk

materials needed to manufacture an item are listed by part number or specification number in a tabular list with an

illustration, as needed.

Section II. MANUFACTURED ITEMS

D-2. FUEL HOSE FABRICATION.

The following hoses are cut from bulk hose using a fine toothed hacksaw or suitable cutting device. Locations and

installation instructions for fuel hoses are found in Para 4-12. Table D-1 lists the fuel hoses.

Table D-1. Fuel System Hoses

Hose Assembly Bulk Hose Cutoff Length

Part Number Part Number Inches cm

65068AX-024 2575-48RL 24 61

47371AXU-018 FC350-04 18 46

EU102958-025 FC350-06 25 64

EU102958-052 FC350-06 52 132

1924600U-034 FC350-10 34 86

56845AXU-005 FC350-10 5 13
TM 9-2320-364-20-5

D-2 

D-3. AIR INTAKE HOSE FABRICATION.

There are two hoses in the air intake system that require fabrication. Both hoses can be cut from bulk stock using a

fine-toothed hacksaw or suitable cutting device. Refer to Para 4-7 for locations and installation instructions.

Table D-2. Air Intake Hoses

Hose Assembly Bulk Hose Cutoff Length

Part Number Part Number Inches cm

21033FXW-120 21020FX 120 305

1732400U-067 FC300-16 67 170

D-4. COOLING SYSTEM HOSES FABRICATION.

The following hoses for the cooling system are cut from bulk hose using a fine-toothed hacksaw or suitable cutting

device. Locations and installation instructions are found in Para 6-8.

Table D-3. Cooling System Hoses

Hose Assembly Bulk Hose Cutoff Length

Part Number Part Number Inches cm

69940AX-048 3230-0293 48 122

4811FX-100 4811FX 100 254

46754AX-U-020 FC350-06 20 51
TM 9-2320-364-20-5

D-3

D-5. SEAL FABRICATION.

Fabricate seals from bulk seal stock listed in Table D-4. Use a suitable cutting tool to cut seal to length required.

Table D-4. Seal, Nonmetallic

Seal Seal Bulk Cutoff Length

Part Number Part Number Inches cm

59747AX-040 101-2203 40 102

59747AX-055 101-2203 55 140

59745AX-040 75000519 40 102

59745AX-055 75000519 55 140

125865A-047 75001366 47 119

125865A-116 75001366 116 295

125865A-160 75001366 160 409
TM 9-2320-364-20-5

D-4 

D-6. EDGING AND MOLDING FABRICATION.

Edging and molding can be fabricated from bulk stock listed in Table D-5. Use suitable cutting tool to cut to length

required.

Table D-5. Edging and Molding

Edging/Molding Edging/Molding Cutoff Length

Part Number Part Number Inches cm

1339700-011 1339700 11 28

26927AX-026 26927AX 26 66

26947BX-002 75000317 2 5

26947BX-003 75000317 3 8

26947BX-004 75000317 4 10

26947BX-005 75000317 5 13

26947BX-006 75000317 6 15

26947BX-017 75000317 17 43

26947BX-018 75000317 18 46

1467160-012 75000317 12 31

42925AX-005 OR40 5 13

27022AX-002 R-422-N 2 5

27002AX-019 R-422-N 19 48

27022AX-024 R-422-N 24 61

27022AX-043 R-422-N 43 109

27022AX-093 R-422-N 93 236

27022AX-101 R-422-N 101 257

27022AX-130 R-422-N 130 330
TM 9-2320-364-20-5

D-5

D-7. LOCKWIRE ROPE

FABRICATION.

The lockwire length is shown in Table D-6. Crimped button stop caps are used to attach the lockwire to other

components. Each application requires two swaging sleeve clips.

NOTES:

1. OBTAIN ALL COMPONENTS REQUIRED TO FABRICATE LOCKWIRE.

2. USE A FINE TOOTHED HACKSAW OR SUITABLE CUTTING DEVICE, AND CUT LOCKWIRE TO LENGTH REQUIRED.

3. SLIDE WIRE THROUGH HOLE IN COMPONENT, UNTIL LOCKWIRE COMES THROUGH OTHER SIDE.

4. SLIDE CAP ONTO LOCKWIRE, UNTIL CAP BOTTOMS AGAINST COMPONENT AND WIRE COMES THROUGH CAP.

5. CRIMP CAP TO LOCKWIRE.

6. SLIDE OPPOSITE END OF WIRE THROUGH ASSEMBLY, AND SLIDE OTHER CAP OVER END OF WIRE.

7. SLIDE WIRE THROUGH HOLE IN COMPONENT, UNTIL LOCKWIRE COMES THROUGH OTHER SIDE.

8. SLIDE CAP ONTO LOCKWIRE, UNTIL CAP BOTTOMS AGAINST COMPONENT AND WIRE COMES THROUGH CAP.

9. CRIMP CAP TO LOCKWIRE.

The following wire rope is cut from bulk stock. Refer to Table D-6 for cutting lengths.

Table D-6. Lockwire Rope

Lockwire Rope Lockwire Rope Cutoff Length

Part Number Part Number Inches cm

1533100-010 1533100 10 25

1533100-015 1533100 15 38

1533100-020 1533100 20 51

1533100-024 1533100 24 61
TM 9-2320-364-20-5

D-6 

D-8. WIRE AND WIRE ASSEMBLIES FABRICATION.

Fabricate from bulk wire stock listed in Table D-7. Use wire cutters to cut wire to required length, then strip ends of

wire 1⁄4 in. (6.35 mm). Crimp the required lugs or terminals onto wire ends.

Table D-7. Wire And Wire Assemblies

Wire/Assembly Bulk Wire Cutoff Length

Part Number Part Number Inches cm

1884540W-012 121782A 12 31

1947560W-012 121782A 12 31

1959390W-012 121782A 12 31

1969600W-012 121782A 12 31

1977300W-010 4127FX 10 25

1974580-013 R-64951 13 33

1974590-005 R-64951 5 13

1978470W-005 R-64951 5 13
TM 9-2320-364-20-5

D-7

D-9. HOSES AND TUBES.

Fabricate hoses and tubes from bulk hose or tube stock listed in Table D-8. Use a fine toothed hacksaw or suitable

cutting device and cut hose/tube to desired length. Place fitting A in vise and screw hose/tube counterclockwise until

hose/tube bottoms out in fitting. Back off 1⁄4 turn. Repeat for fitting B.

Table D-8. Hoses and Tubes

Hose/Tube Bulk Hose Cutoff Length

Part Number Part Number Inches cm

5113689-12 1525-6 12 31

21021FX-026 2102CFX 26 66

32850AX-014 22020 14 36

32850AX-016 22020 16 41

32850AX-030 22020 30 76

32850AX-036 22020 36 91

32850AX-51 22020 51 130

31270AX-029 31270AX 29 74

31270AX-082 31270AX 83 208

31270AX-096 31270AX 96 244

31270AX-140 31270AX 140 356

69940AX-006 3230-0293 6 15

69940AX-065 3230-0293 65 165

31271AX-040 3250-101 40 102

31271AX-047 3250-101 47 119

31271AX-053 3250-101 53 135

31271AX-092 3250-101 92 234
TM 9-2320-364-20-5

D-8 

Table D-8. Hoses and Tubes

Hose/Tube Cutoff Length Bulk Hose

Part Number Part Number Inches cm

31271AX-150 3250-101 150 381

AAAC0085 51995757 85 216

AAAC0105 5199575 105 267

AAAC0190 5199575 190 483

AAAC0260 5199575 260 660

AAAE0090 5199575 90 229

1944510 70-062 Variable

1944520 70-062 Variable

23319FX-012 C604-200 BLK 12 31

23319FX-023 C604-200 BLK 23 58

23319FX-029 C604-200 BLK 29 74

23319FX-244 C604-200 BLK 244 620

23319FX-257 C604-200 BLK 257 653

23323FX-008 C606 BLACK 8 20

23323FX-008 C606 BLACK 8 20

23323FX-010 C606 BLACK 10 25

23323FX-010 C606 BLACK 10 25

23323FX-012 C606 BLACK 12 31

23323FX-014 C606 BLACK 14 36

23323FX-019 C606 BLACK 19 48

23323FX-022 C606 BLACK 22 56

23323FX-026 C606 BLACK 26 66

23323FX-030 C606 BLACK 30 76

23323FX-033 C606 BLACK 33 84

23323FX-042 C606 BLACK 42 107

23323FX-042 C606 BLACK 42 107

23323FX-044 C606 BLACK 44 112

23323FX-046 C606 BLACK 46 117

23323FX-050 C606 BLACK 50 127

23323FX-052 C606 BLACK 52 132

23323FX-055 C606 BLACK 55 140

23323FX-057 C606 BLACK 57 145

23323FX-060 C606 BLACK 60 152

23323FX-060 C606 BLACK 60 152

23323FX-082 C606 BLACK 82 208

23323FX-087 C606 BLACK 87 221
TM 9-2320-364-20-5

D-9

Table D-8. Hoses and Tubes

Hose/Tube Cutoff Length Bulk Hose

Part Number Part Number Inches cm

23323FX-089 C606 BLACK 89 226

23323FX-148 C606 BLACK 148 376

23323FX-159 C606 BLACK 159 404

23323FX-163 C606 BLACK 163 414

23323FX-200 C606 BLACK 200 508

23323FX-335 C606 BLACK 335 851

23323FX-377 C606 BLACK 377 958

198872A U-200 FC300-04 20 51

115134A W-004 FC300-04 4 10

1732400 U-067 FC300-16 67 170

1620950 U-099 FC350-04 99 252

47371AX U-055 FC350-04 5 13

47371AX U-006 FC350-04 6 15

47371AX U-012 FC350-04 12 31

47371AX U-017 FC350-04 17 43

47371AX U-018 FC350-04 18 46

47371AX U-120 FC350-04 120 305

60264AX U-031 FC350-04 31 79

60264AX U-034 FC350-04 34 86

60264AX U-054 FC350-04 54 137

60264AX U-057 FC350-04 57 145

60264AX U-063 FC350-04 63 160

60264AX U-082 FC350-04 82 208

60296AX U-029 FC350-04 29 74

60296AX U-036 FC350-04 36 91

60296AX U-061 FC350-04 61 155

1780700 U-032 FC350-06 32 81

1780700 U-035 FC350-06 35 89

1780700 U-039 FC350-06 39 99

1780700 U-041 FC350-06 41 104

1782400 U-022 FC350-06 22 56

1782410 U-021 FC350-06 21 53

1782450 U-025 FC350-06 25 64

47336AX-060 FC350-06 60 152

47554AX U-020 FC350-06 20 51

118971A U-022 FC350-06 22 56
TM 9-2320-364-20-5

D-10 

Table D-8. Hoses and Tubes

Hose/Tube Cutoff Length Bulk Hose

Part Number Part Number Inches cm

118971A U-095 FC350-06 95 241

119784A U-010 FC350-06 10 25

119784A U-021 FC350-08 21 53

119784A U-047 FC350-08 47 119

1782340 U-019 FC350-08 19 48

1782360 U-020 FC350-08 20 51

1921290 U-025 FC350-08 25 64

1936150 U-032 FC350-08 32 81

1936150 U-034 FC350-08 34 86

1936150 U-038 FC350-08 38 97

1936150 U-040 FC350-08 40 102

69390AX U-006 FC350-08 6 15

69390AX U-019 FC350-08 19 48

69390AX U-020 FC350-08 20 51

69390AX U-020 FC350-08 20 51

69390AX U-021 FC350-08 21 53

69390AX U-025 FC350-08 25 37

1780720 U-020 FC350-10 20 51

1780720 U-051 FC350-10 51 130

1782370 U-037 FC350-10 37 94

1782380 U-031 FC350-10 31 79

1782390 U-020 FC350-10 20 51

1782420 U-039 FC350-10 39 99

1782430 U-031 FC350-10 31 79

1782440 U-019 FC350-10 19 48

1924600 U-090 FC350-10 90 229

47750AX U-009 FC350-10 9 23

58989AX U-020 FC350-10 20 51

58989AX U-034 FC350-10 34 86

58989AX U-064 FC350-10 64 163

66798AX U-020 FC350-10 20 51

66798AX U-025 FC350-10 25 64

66798AX U-030 FC350-10 30 76

66798AX U-077 FC350-10 77 196

1780710 U-082 FC350-12 82 208

1780710 U-083 FC350-12 83 211
TM 9-2320-364-20-5

D-11

Table D-8. Hoses and Tubes

Hose/Tube Cutoff Length Bulk Hose

Part Number Part Number Inches cm

47369AX U-127 FC350-12 127 323

61608AX U-093 FC350-12 93 236

61608AX U-142 FC350-12 142 361

47468AX U-011 FC350-16 11 28

47468AX U-022 FC350-16 22 56

47468AX U-045 FC350-16 45 114

47468AX U-046 FC350-16 46 117

47468AX U-089 FC350-16 89 226

47213AX-012 NT10012-50FT 12 31

47213AX-015 NT10012-50FT 16 41

47213AX-021 NT10012-50FT 21 53

47213AX-023 NT10012-50FT 23 58

47213AX-025 NT10012-50FT 25 64

47213AX-025 NT10012-50FT 25 64

47213AX-060 NT10012-50FT 60 152

47213AX-073 NT10012-50FT 73 185

47213AX-073 NT10012-50FT 73 185

47213AX-173 NT10012-50FT 173 439

47213AX-194 NT10012-50FT 194 493

1656500-128 PFT-10B-GRN 128 325

1656500-183 PFT-10B-GRN 183 465

1656490-102 PFT-10B-RED 102 259

1656490-202 PFT-10B-RED 202 513

1656490-257 PFT-10B-RED 257 653

1656470-030 PFT-4A-BLU 30 76

1656470-104 PFT-4A-BLU 104 264

1656470-115 PFT-4A-BLU 115 292

1656470-139 PFT-4A-BLU 139 353

1605260-008 PFT-4A-GRN 8 20

1605330-020 PFT-4A-ORG 20 51

1605330-040 PFT-4A-ORG 40 102

1605330-071 PFT-4A-ORG 71 180

1605330-112 PFT-4A-ORG 112 285

1605330-124 PFT-4A-ORG 124 315

1605170-007 PFT-4A-RED 7 18

1605270-023 PFT-6B-GRN 23 58
TM 9-2320-364-20-5

D-12 

Table D-8. Hoses and Tubes

Hose/Tube Cutoff Length Bulk Hose

Part Number Part Number Inches cm

1605270-028 PFT-6B-GRN 28 71

1605270-056 PFT-6B-GRN 56 142

1605270-057 PFT-6B-GRN 57 145

1605270-100 PFT-6B-GRN 100 254

1605270-108 PFT-6B-GRN 108 274

1605270-146 PFT-6B-GRN 146 371

1605320-205 PFT-6B-ORG 205 521

1605160-012 PFT-6B-RED 12 31

1605160-014 PFT-6B-RED 14 36

1605160-030 PFT-6B-RED 30 76

1605160-031 PFT-6B-RED 31 79

1605160-047 PFT-6B-RED 47 119

1605160-048 PFT-6B-RED 48 122

1605160-049 PFT-6B-RED 49 125

1605160-055 PFT-6B-RED 55 140

1605160-102 PFT-6B-RED 102 259

1605160-103 PFT-6B-RED 103 262

1605160-114 PFT-6B-RED 114 290

1605160-165 PFT-6B-RED 165 419

1605160-213 PFT-6B-RED 213 541

1605300-026 PFT-6B-YEL 26 66

1605300-066 PFT-6B-YEL 66 168

1605300-070 PFT-6B-YEL 70 179

1605300-129 PFT-6B-YEL 129 328

1605300-132 PFT-6B-YEL 132 335

1605300-150 PFT-6B-YEL 150 381

1605300-022 PFT-8B-BLU 22 56

1605300-316 PFT-8B-BLU 316 803

W-22-13 W-22 13 33

W-22-9 W-22 9 23

40AW168-010 W-22-L 10 25

40AW168-050 W-22-L 50 127

40AW168-19 W-22-L 19 48

40AW168-27 W-22-L 27 69

40AW168-45 W-22-L 45 114
TM 9-2320-364-20-5

D-13

D-10. WOODEN BLOCKS.

b. Fabricate from MML751 lumber stock.

b. Using saw and standard planing machine, cut stock to size required in Table D-9.

Table D-9. Wooden Blocks

Para

Number

Finished Dimensions of Block

In. (cm)

2-28 4 by 4 by 12 in.

(10 by 10 by 30 cm)

5-2 2 by 4 by 6 in.

(5 by 10 by 15 cm)

13-2 4 by 4 by 12 in.

(10 by 10 by 30 cm)
TM 9-2320-364-20-5

D-14 

D-11. STEERING STOP PLATE.

Fabricate steering stop plate from 1/8 in. (3mm) thick mild steel stock. Using a hacksaw, cut to dimension shown. 

File off rough edges.

D-12. BAR-BRAKE RETURN SPRING

 REMOVAL TOOL.

Fabricate bar-brake return spring removal tool from ASTM A36 angle aluminum. Using a hacksaw, cut to dimension

shown. File off rough edges.
TM 9-2320-364-20-5

D-15

D-13. ADAPTER,TORQUE, 3/4 IN. DRIVE.

Fabricate torque adapter from Extension, P/N L32, NSN 5120-00-273-9208, and bar stock, Spec 23 or better. Cut part

A and part B to dimensions shown.
TM 9-2320-364-20-5

D-16 

D-14. JUMPER HARNESS (DDEC III).

(1) Fabricate from 16-gage wire.

(2) Using wire cutters, cut five pieces of 16-gage wire to 180 in. (457 cm).

(3) Strip both ends of each wire .25 inch (6.4 mm).

(4) Crimp five terminals (PN 12077413) and five cable seals (PN 12015193) on wires.

(5) Insert terminals and cable seals into connector body (PN 12124634) as illustrated.

(6) Secure terminals and cable seals in connector body with secondary lock (PN 12052816).

(7) Attach terminals (PN D-351-38) to other end of wires 150, 150 & 151, and 240 & 241, as illustrated.
TM 9-2320-364-20-5

E-1

APPENDIX E

TORQUE LIMITS

E-1. SCOPE.

This section provides general torque limits for the screws, hoses and fittings used on the truck. Special torque limits

are listed in the maintenance procedures for applicable components. The general torque limits given in this appendix

shall be used when specific torque limits are not indicated in the maintenance procedure. These general torque limits

cannot be applied to screws that retain rubber components. The rubber components will be damaged before the torque

limit is reached. If a special torque limit is not given in the maintenance instructions, tighten the screw or nut until it

touches the metal bracket then tighten it one more turn.

E-2. TORQUE LIMITS.

Table E-1 lists the torque limits for wet flange nuts. Table E-2 lists the torque limits for wet socket head capscrews.

Table E-3 lists dry torque limits for capscrews. Dry torque limits are used on screws that do not have high pressure

lubricants applied to the threads. Table E-4 lists wet torque limits for capscrews. Wet torque limits are used on screws

that have high pressure lubricants applied to the threads. Table E-5 lists the torque limits for SAE 37 degree flare hose

connections. Table E-6 lists the torque limits for SAE 45 degree flare hose connections. Table E-7 lists the torque

limits for ORS preformed packing face seal hose connections. Table E-8 lists the torque limits for NPSM swivel

connections.

E-3. HOW TO USE TORQUE TABLE.

a. Screws and Nuts.

(1) Measure the diameter of the screw you are

installing with a ruler.
SOC HEAD/12 PT.

SOC FLAT HEAD

TM 9-2320-364-20-5

E-2 

E-3. HOW TO USE TORQUE TABLE (CONT).

(2) Measure out one inch with a ruler and count

the number of threads per inch.

(3) Under the heading SIZE, look down the left

hand column until you find the diameter of

the screw you are installing (there will

usually be two lines beginning with the

same size).

(4) In the second column under SIZE, find the

number of threads per inch that matches the

number of threads per inch you counted in

Step 2. (Not required for metric screws).

(5) To find the grade screw you are installing,

match the markings on the head to the

correct picture of CAPSCREW HEAD

MARKINGS on the torque table.

(6) Look down the column under the picture

you found in Step 5. until you find the

torque limit (lb-ft or N.

m) for the diameter

and threads per inch of the screw you are

installing.

(7) Use wet torque values.

Table E-1. Torque Limits For Wet Flange Nuts

SPIRALOCK FLANGE DIAMETER THREADS TORQUE

NUT MARKINGS PER INCH

GRADE 8 IN. MM LB-FT N.m

1/4 6.35 20 15 20

5/16 7.94 18 25 34

3/8 9.65 16 45 61

1/2 12.70 13 110 149

5/8 15.87 11 210 285

3/4 19.05 10 375 508

Table E-2. Torque Limits For Wet Socket Head Cap Screws

TORQUE IN FT. LBS. (CAP SCREWS) LUBED

SIZE SOC HD OR 12 PT SOC FLAT HD

.10-24 5 2.5

.25-20 12 6

.31-18 25 12

.38-16 44 22

.50-13 70 36

.56-12 106 53

.62-11 212 106

.75-10 375 187

1.00-8 781
TM 9-2320-364-20-5

E-3

b. Hoses and Fittings.

NOTE

Most fluid piping system sizes are

measured by dash numbers. These

are universally used abbreviations

for the size of the component

expressed as the numerator of the

fraction with the denominator

always being 16. For example, a

-04 port is 4/16 or 1/4-inch. Dash

numbers are usually nominal (in

name only) and are abbreviations

that make ordering of components

easier.

(1) Measure the I.D./O.D. diameter with a

caliper as shown.

(2) Under the heading MALE THREAD O.D.

and FEMALE THREAD I.D., match the

measurements with the row in table to

determine proper torque.

(3) To find the sealing surface angle, use a

protractor and measure the sealing surface

parallel to the center line of the fitting.
TM 9-2320-364-20-5

E-4 

Table E-3. Torque Limits For Dry Fasteners

SIZE

TORQUE

SAE GRADE

NO. 2

SAE GRADE

NO. 5

SAE GRADE

NO. 6 or 7

SAE GRADE

NO. 8

DIA.

INCHES

THREADS

PER INCH MILLIMETERS

POUNDS

FEET

NEWTON

METERS

POUNDS

FEET

NEWTON

METERS

POUNDS

FEET

NEWTON

METERS

POUNDS

FEET

NEWTON

METERS

1/4 20 6.35 5 7 8 11 10 14 12 16

1/4 28 6.35 6 9 10 14 12 16 14 19

5/16 18 7.94 11 15 17 23 21 28 25 34

5/16 24 7.94 12 16 19 26 24 33 25 34

3/8 16 9.53 20 27 30 41 40 54 45 61

3/8 24 9.53 23 31 35 47 45 61 50 68

7/16 14 11.11 30 41 50 68 60 81 70 95

7/16 20 35 47 55 75 70 95 80 108

1/2 13 12.70 50 68 75 102 95 129 110 149

1/2 20 55 75 90 122 100 136 120 163

9/16 12 14.29 65 88 110 149 135 183 150 203

9/16 18 75 102 120 163 150 203 170 231

5/8 11 15.88 90 122 150 203 190 258 220 298

5/8 18 100 136 180 244 210 285 240 325

3/4 10 19.05 160 217 260 353 320 434 380 515

3/4 16 180 244 300 407 360 488 420 569

7/8 9 22.23 140 190 400 542 520 705 600 814

7/8 14 155 210 440 597 580 786 660 895

1 8 25.40 220 298 580 786 800 1085 900 1220

1 12 240 325 640 868 860 1166 1000 1356

1-1/8 7 25.58 300 407 800 1085 1120 1519 1280 1736

1-1/8 12 340 461 880 1193 1260 1709 1440 1953

1-1/4 7 31.75 420 597 1120 1519 1580 2142 1820 2468

1-1/4 12 460 624 1240 1681 1760 2387 2000 2712

1-3/8 6 34.93 560 759 1460 1980 2080 2820 2380 3227

1-3/8 12 640 868 1680 2278 2380 3227 2720 3688

1-1/2 6 38.10 740 1003 1940 2631 2780 3770 3160 4285

1-1/2 12 840 1139 2200 2983 3100 4204 3560 4827
TM 9-2320-364-20-5

E-5

Table E-4. Torque Limits For Wet Fasteners

SIZE

TORQUE

SAE GRADE

NO. 2

SAE GRADE

NO. 5

SAE GRADE

NO. 6 or 7

SAE GRADE

NO. 8

DIA.

INCHES

THREADS

PER INCH MILLIMETERS

POUNDS

FEET

NEWTON

METERS

POUNDS

FEET

NEWTON

METERS

POUNDS

FEET

NEWTON

METERS

POUNDS

FEET

NEWTON

METERS

1/4 20 6.35 4 6 6 8 8 11 9 12

1/4 28 6.35 5 7 7 9 9 12 10 14

5/16 18 7.94 8 11 13 18 16 22 18 24

5/16 24 7.94 9 12 14 19 18 24 20 27

3/8 16 9.53 15 20 23 31 30 41 35 47

3/8 24 9.53 17 23 25 34 30 41 35 47

7/16 14 11.11 24 33 35 47 45 61 55 75

7/16 20 25 34 40 54 50 68 60 81

1/2 13 12.70 35 47 55 75 70 95 80 108

1/2 20 40 54 65 88 80 108 90 122

9/16 12 14.29 50 68 80 108 100 136 110 149

9/16 18 55 75 90 122 110 149 130 176

5/8 11 15.88 70 95 110 149 140 190 170 231

5/8 18 80 108 130 176 160 217 180 244

3/4 10 19.05 120 163 200 271 240 325 280 380

3/4 16 140 190 220 298 280 380 320 434

7/8 9 22.23 110 149 300 407 400 542 460 624

7/8 14 120 163 320 434 440 597 500 678

1 8 25.40 160 217 440 597 600 814 680 922

1 12 170 231 480 651 660 895 740 1003

1-1/8 7 25.58 220 298 600 814 840 1139 960 1320

1-1/8 12 260 353 660 895 940 1275 1080 1464

1-1/4 7 31.75 320 434 840 1139 1100 1492 1360 1844

1-1/4 12 360 488 920 1248 1320 1790 1500 2034

1-3/8 6 34.93 420 570 1100 1492 1560 2115 1780 2414

1-3/8 12 460 624 1260 1709 1780 2414 2040 2776

1-1/2 6 38.10 560 760 1460 1980 2080 2820 2360 3200

1-1/2 12 620 841 1640 2224 2320 3146 2660 3607
TM 9-2320-364-20-5

E-6 

Table

E-5. Torque Limits For 37 Degree Flare Hose Connections

INCH

SIZE

DASH

NO.

THREAD

SIZE

TORQUE

LB.FT.

TORQUE

N.m

1/4 04 7/16-20 11-12 15-16

3/8 06 9/16-18 18-21 24-28

1/2 08 3/4-16 36-39 49-53

5/8 10 7/8-14 57-62 77-84

3/4 12 1 1/16-12 79-87 107-118

7/8 14 1 3/16-12 83-91 113-123

1 16 1 5/16-12 108-113 146-153

1 1/4 20 1 5/8-12 127-133 172-180

1 1/2 24 1 7/8-12 158-167 214-224

2 32 2 1/2-12 245-258 332-350

Table E-6. Torque Limits For 45 Degree Flare Hose Connections

INCH

SIZE

DASH

NO.

THREAD

SIZE

TORQUE

LB.FT.

TORQUE

N.

m

1/4 04 7/16-20 8-9 11-12

3/8 06 5/8-18 18-20 24-27

1/2 08 3/4-16 36-38 49-51

5/8 10 7/8-14 52-54 70-73

3/4 12 1 1/16-14 71-74 97-100
TM 9-2320-364-20-5

E-7/(E-8 blank)

Table E-7. Torque Limits For ORS Preformed Packing Face Seal Hose Connections

INCH

SIZE

DASH

NO.

THREAD

SIZE

TORQUE

LB.FT.

TORQUE

N.m

1/4 04 9/16-18 10-12 14-16

3/8 06 11/16-16 18-20 24-27

1/2 08 13/16-16 32-35 43-47

5/8 10 1-14 46-50 62-68

3/4 12 1 3/16-12 65-70 88-95

1 16 1 7/16-12 108-113 146-153

1 1/4 20 1 11/16-12 127-133 172-180

1 1/2 24 2-12 158-167 214-226

Table E-8. Torque Limits For NPSM Swivel Connections

INCH

SIZE

DASH

NO.

THREAD

SIZE

TORQUE

LB.FT.

TORQUE

N.

m

1/8 02 1/8-27 3-4 4-5

1/4 04 1/4-18 10-11 14-15

3/8 06 3/8-18 16-18 22-24

1/2 08 1/2-14 25-27 34-37

3/4 12 3/4-14 46-48 62-65

1 16 1-1 1/2 80-83 108-113

1 1/4 20 1 1/4-11/2 130-134 176-182

1 1/2 24 1 1/2-11/2 160-164 217-222

2 32 2-11/2 170-174 231-240

TM 9-2320-364-20-5

F-1

APPENDIX F

MANDATORY REPLACEMENT PARTS

Section I. INTRODUCTION

F-1. SCOPE.

This appendix lists all mandatory replacement parts required for performance of Unit Support Maintenance of the 

PLS truck. It authorizes the requisitioning, issue, and disposition of consumable repair parts. All consumable repair

parts listed in the maintenance tasks are listed here for ease of reference.

F-2. EXPLANATION OF COLUMNS (SECTION II).

a. Column (1) - Replacement Part Reference Code. This number is assigned to the entry in the listing and is

referenced in the narrative task box to identify the part e.g., Clamp (Item 12, Appendix F).

b. Column (2) - Nomenclature. Indicates the federal item name and, if required, a description to identify the 

item.

c. Column (3) - Part Number. This is the vendor number assigned to the item.

d. Column (4) - National Stock Number. This is the National Stock Number assigned to the item; use it to

request or requisition the item.
TM 9-2320-364-20-5

F-2 

Section II. MANDATORY REPLACEMENT PARTS LIST 

(1)

Index No.

(2)

Nomenclature

(3)

Part Number

(4)

National Stock Number

1 Belt Set, (3) 3113452

2 Belt Set, Vee, (2) 1934800 3030-00-492-8106

3 Bushing 1X1/4PTR-B 4730-01-338-1459

4 Bushing 12406FX 5365-00-402-5376

5 Bypass Valve A-DF-216 4820-01-359-1067

6 Cable, Drain Valve SN-153 4010-01-348-6039

7 Cap, End Splice 7040700

8 Capacitor 1972630 5910-01-364-9163

9 Channel 126916B 2540-01-155-5836

10 Channel, Rubber 101-2203 5330-01-267-7542

11 Channel, Rubber 126890 5330-01-155-1938

12 Clamp 24433 5340-01-131-8313

13 Clamp 32664AX 5340-01-131-8312

14 Clamp 5137620 5340-01-114-5623

15 Clamp 700-118 4730-01-212-8276

16 Clamp 700-120 4730-01-199-1458

17 Clamp 700-88 5340-01-355-7648

18 Clamp 90359-A 4730-01-353-9723

19 Clamp B54-32780 4730-00-278-2523

20 Clamp C0V-2515 5340-01-060-8686

21 Clamp 51689AX 5340-01-167-4146

22 Clamp, Loop H360-4-2 5340-01-151-8391

23 Clip, Cable 57972 5340-01-193-9654

24 Clip, Push H360-6-2 5340-01-224-8368

25 Contact, Electrical 12034051 5940-01-342-0712

26 Contact, Electrical 12084563 5999-01-321-1925

27 Contact, Electrical 12089305 5999-01-319-7394

28 Cross and Bearing 5-103X 2530-01-244-4949

29 Dust Boot 12010293 5975-01-226-8078

30 Dust Boot 12015323 5975-01-310-5011

31 Element, Filter 100696-E 2940-01-213-1135

32 Element, Filter 1317673 2940-01-347-7460
TM 9-2320-364-20-5

F-3

Section II. MANDATORY REPLACEMENT PARTS LIST (Cont)

(1)

Index No.

(4)

National Stock Number

(3)

Part Number

(2)

Nomenclature

33 Element, Filter 2020-PMOR 2910-01-344-5791

34 Element, Strainer 5106910 4730-01-160-5668

35 Fastener And Seal Kit 50009501 5340-01-363-9215

36 Fastener And Seal Kit 50009503 5330-01-358-9309

37 Fastener And Seal Kit 50009504 5330-01-358-9308

38 Filter and Gasket 23518524 2940-01-314-1345

39 Filter Element Kit MTP-95-551 4330-01-026-6371

40 Filter, Fuel 23518481 2910-01-423-2859

41 Filter, Hydraulic 1314130 4330-01-232-8305

42 Fitting, Lubrication MS15002-3 4730-00-172-0015

43 Gasket 02343-02 5330-01-193-5315

44 Gasket 0-615C46XA 5330-01-348-8345

45 Gasket 11007B 5330-01-344-0539

46 Gasket 1198559 5330-01-358-8219

47 Gasket 1199479 5330-01-234-2618

48 Gasket 12357897 6220-01-319-5509

49 Gasket 14079550 5330-00-107-3925

50 Gasket 1728230 5330-01-347-9858

51 Gasket 1958330 5330-01-358-5561

52 Gasket 23016336 5330-01-328-7634

53 Gasket 5100860 5300-01-058-8267

54 Gasket 5104081 5330-01-078-7186

55 Gasket 5117786 5330-00-781-7117

56 Gasket 5130995 5330-00-980-1546

57 Gasket 5136678 5330-00-198-7953

58 Gasket 5766-1211-6 5330-01-242-2698

59 Gasket 731740-002

60 Gasket 7716570 5330-00-771-6570

61 Gasket 8921312 5330-01-206-3263

62 Gasket 8924413

63 Gasket 92-158 5330-01-058-7118

64 Gasket A/281 5330-01-352-1997
TM 9-2320-364-20-5

F-4 

Section II. MANDATORY REPLACEMENT PARTS LIST (Cont)

(1)

Index No.

(4)

National Stock Number

(3)

Part Number

(2)

Nomenclature

65 Gasket DIN7603A 14X18

66 Gasket EE100969 9330-01-185-4466

67 Gasket M25988/1-246 5330-01-189-6351

68 Gasket NE-71A 5330-01-277-5103

69 Gasket Strip 2050690 5330-01-394-8346

70 Gasket, Breather Filler FB-7 5330-01-406-8221

71 Gasket, Headlight 1400940 5330-01-234-7640

72 Grommet 459-A 5330-01-049-0550

73 Guide Assy, Pawl NA1779M195 3040-01-351-4061

74 Guide Assy, Pawl NA22297U4597 3040-01-350-3980

75 Hardware, Mounting GS-2655 5340-01-365-3144

76 Housing, Tach 5106771 6680-01-086-4470

77 Insulation 1949200 2540-01-370-6144

78 Insulation 1949220 2540-01-367-7392

79 Insulation 1949230 2540-01-368-9962

80 Insulation C04610 2510-01-389-0708

81 Isolator 23512307 5340-01-414-2177

82 Journal And Bearing Kit 5-438X 2520-01-339-0533

83 Journal And Bearing Kit 5-510X 2520-01-339-0532

84 Journal And Bearing Kit 5-515X 2520-01-289-8307

85 Key 1363190 5315-01-165-2188

86 Kit, Mounting 893236 4810-01-400-6041

87 Kit, Packing SK-10-4

88 Lamp E-013-001 6210-01-345-6315

89 Locknut 0-952A14 5310-00-725-9479

90 Locknut 10095 5310-01-063-1755

91 Locknut 110310A 5310-01-159-8178

92 Locknut 110311A 5310-01-111-0645

93 Locknut 110312A 5310-01-150-5918

94 Locknut 112556A 5310-01-372-6378

95 Locknut 114358AX

96 Locknut 115307A 5310-01-151-1036
TM 9-2320-364-20-5

F-5

Section II. MANDATORY REPLACEMENT PARTS LIST (Cont)

(1)

Index No.

(4)

National Stock Number

(3)

Part Number

(2)

Nomenclature

97 Locknut 1244954-2 5310-00-074-1387

98 Locknut 1333510 5310-01-340-5671

99 Locknut 1334320 5310-01-161-9123

100 Locknut 1408910 5310-01-111-0645

101 Locknut 1437220

102 Locknut 1525130 5310-01-357-8840

103 Locknut 1571850 5310-01-288-5096

104 Locknut 1571870 5310-01-352-7732

105 Locknut 1598030 5310-01-342-8595

106 Locknut 1600460 5310-01-346-9445

107 Locknut 1605420 5310-00-542-0087

108 Locknut 203145 5310-00-012-0368

109 Locknut 21NE-040 5310-01-066-6759

110 Locknut 22NM04 5310-00-207-9341

111 Locknut 2-X-5731 5310-00-447-4251

112 Locknut 40X-1239 5310-01-377-1996

113 Locknut 41NE120 5310-00-530-0239

114 Locknut 434-A 5310-01-063-8970

115 Locknut 44NTE-1210 5310-01-346-3789

116 Locknut 5340910 5310-01-280-6538

117 Locknut 60860AX

118 Locknut 60861A 5310-01-061-5678

119 Locknut 7-660-082504 5310-01-354-8734

120 Locknut 767HX1 5310-01-058-3183

121 Locknut 76985 5310-00-432-3959

122 Locknut 88881 5310-01-349-0759

123 Locknut 93604342 5310-01-081-5351

124 Locknut AN365-1024A 5310-00-208-1918

125 Locknut ATS2-518 5340-01-196-0380

126 Locknut F41NE2076-1216 5310-01-357-4700

127 Locknut L-10-MNS-500-X-1 5310-01-345-2350

128 Locknut MS17828-7C 5310-01-117-5055
TM 9-2320-364-20-5

F-6 

Section II. MANDATORY REPLACEMENT PARTS LIST (Cont)

(1)

Index No.

(4)

National Stock Number

(3)

Part Number

(2)

Nomenclature

129 Locknut MS21044C08 5310-00-982-6814

130 Locknut MS51849-74 5305-00-470-3321

131 Locknut MS51922-1 5310-00-088-1251

132 Locknut MS51922-17 5310-00-087-4652

133 Locknut MS51922-9 5310-00-984-3806

134 Locknut MS51943-31 5310-00-061-4560

135 Locknut MS51968-14 5310-00-732-0560

136 Locknut N08 5310-00-185-6389

137 Locknut N9406 5310-01-362-6171

138 Locknut N9410 5310-01-348-8398

139 Locknut SN104-NM-22 5310-01-355-0217

140 Locknut T893R 5310-01-288-1116

141 Locknut TLA-1213-GRC 5310-01-081-8244

142 Locknut TLA-3410-GRC 5310-01-080-5747

143 Locknut TLA-3816-GRC 5310-01-222-9097

144 Locknut TLA-7809-GRC 5310-01-107-3586

145 Locknut V75700689 5310-01-345-3757

146 Locknut XB-769 5310-01-150-8599

147 Lockscrew 11504603 5305-01-336-6757

148 Lockscrew 31 WLFS 1420 5310-01-393-7077

149 Lockwasher 100-0000-051 5310-00-045-3299

150 Lockwasher 114021 5310-01-081-0798

151 Lockwasher 1244954-2 5310-00-074-1387

152 Lockwasher 1344950 5305-01-155-6107

153 Lockwasher 138526 5310-00-013-8526

154 Lockwasher 1459-254 5310-00-171-1734

155 Lockwasher 16FW008032 5310-00-988-8820

156 Lockwasher 1978HX

157 Lockwasher 201506 5310-01-373-2539

158 Lockwasher 201946 5310-00-013-8572

159 Lockwasher 202210 5310-01-101-2490

160 Lockwasher 210104 5310-01-K49-2583

161 Lockwasher 2239HX 5310-00-209-1218
TM 9-2320-364-20-5

F-7

Section II. MANDATORY REPLACEMENT PARTS LIST (Cont)

(1)

Index No.

(4)

National Stock Number

(3)

Part Number

(2)

Nomenclature

162 Lockwasher 2249HX

162.1 Lockwasher 2250HX

163 Lockwasher 2251HX 5310-01-354-3729

164 Lockwasher 2434 5310-00-775-5139

165 Lockwasher 318B 5310-01-061-5302

166 Lockwasher 318BX

167 Lockwasher 3231 5310-00-032-1814

168 Lockwasher 351AX 5310-01-129-0450

169 Lockwasher 352A 5310-01-081-1283

170 Lockwasher 352AX 5310-01-081-1283

171 Lockwasher 353AX 5310-00-582-5965

172 Lockwasher 354AX 5310-01-068-8446

173 Lockwasher 355AX 5310-01-133-2130

174 Lockwasher 362AX 5310-01-062-3379

175 Lockwasher 371AX 5310-00-775-5139

176 Lockwasher 62ANBH-4 4730-01-349-7765

177 Lockwasher 777-A 5310-01-061-4481

178 Lockwasher 7-950-160050 5310-01-292-4150

179 Lockwasher 8104200064 5310-01-358-6624

180 Lockwasher 93613642 5310-01-068-8446

181 Lockwasher C-972 5310-01-210-7427

182 Lockwasher HLKW025EG 5310-01-105-2652

183 Lockwasher L051275 5310-10-244-8747

184 Lockwasher MS35333-37 5310-00-579-0079

185 Lockwasher MS35333-40 5310-00-550-1130

186 Lockwasher MS35333-51 5310-00-655-6927

187 Lockwasher MS35335-30 5310-00-209-0788

188 Lockwasher MS35335-31 5310-00-596-7693

189 Lockwasher MS35335-49 5310-00-582-6714

190 Lockwasher MS35338-100 5310-00-261-8278

191 Lockwasher MS35338-103 5310-00-184-8971

192 Lockwasher MS35338-15 5310-00-012-1326
TM 9-2320-364-20-5

F-8 

Section II. MANDATORY REPLACEMENT PARTS LIST (Cont)

(1)

Index No.

(4)

National Stock Number

(3)

Part Number

(2)

Nomenclature

193 Lockwasher MS35338-42 5310-00-045-3299

194 Lockwasher MS35338-43 5310-00-045-3296

195 Lockwasher MS35338-44 5310-00-582-5965

196 Lockwasher MS35338-45 5310-00-407-9566

197 Lockwasher MS35338-46 5310-00-637-9541

198 Lockwasher MS35338-48 5310-00-584-5272

199 Lockwasher MS35338-50 5310-00-820-6653

200 Lockwasher MS35338-51 5310-00-584-7888

201 Lockwasher MS35338-6 5310-00-010-3319

202 Lockwasher MS35338-8 5310-00-261-7340

203 Lockwasher MS35649-204 5310-00-954-9760

204 Lockwasher MS45904-60 5310-00-080-9786

205 Lockwasher MS51413-8

206 Lockwasher MS51848-12 5310-00-688-2195

207 Lockwasher N405P13C16 5310-01-044-2295

208 Lockwasher N9015 5310-01-046-0186

209 Lockwasher N9018 5310-01-032-4827

210 Lockwasher N9461 5310-01-348-8392

211 Lockwasher W08 5310-01-355-8794

212 Lockwasher (#10 Stud) 85020 5310-01-373-6180

213 Nut MS35650-103 5310-00-988-2652

214 Nut MS51967-32 5310-00-762-6242

215 Nut MS51967-35 5310-00-762-6241

216 Nut MS51967-38 5310-00-762-6247

217 Nut, Push On C12044-017-4 5310-00-110-8742

218 Nut, Stop A1300R

219 Nut, Tenz 1244954-2 5310-00-074-1387

220 Packing, Preformed 0526453-00 5330-00-071-6651

221 Packing, Preformed 11-222 5330-00-198-6190

222 Packing, Preformed 11350 5330-01-147-6003

223 Packing, Preformed 11639519-1 5330-00-463-0200

224 Packing, Preformed 11639519-2 5330-00-462-0907
TM 9-2320-364-20-5

F-9

Section II. MANDATORY REPLACEMENT PARTS LIST (Cont)

(1)

Index No.

(4)

National Stock Number

(3)

Part Number

(2)

Nomenclature

225 Packing, Preformed 2014N103-70 5330-00-213-8722

226 Packing, Preformed 2-016N552-90 5330-01-115-8225

227 Packing, Preformed 2-021N0552 4730-00-541-0938

228 Packing, Preformed 22012-6 5330-00-200-8125

229 Packing, Preformed 22012-8 5330-00-996-8627

230 Packing, Preformed 2-238N674-70 5330-00-172-7223

231 Packing, Preformed 22617-10 5330-01-040-4772

232 Packing, Preformed 22617-12 5330-00-228-7196

233 Packing, Preformed 22617-16 5330-01-168-0885

234 Packing, Preformed 22617-20 5330-01-168-1802

235 Packing, Preformed 22617-4

236 Packing, Preformed 22617-6 5330-01-198-8439

237 Packing, Preformed 22617-8 5330-01-224-2273

238 Packing, Preformed 2282320

239 Packing, Preformed 2282330

240 Packing, Preformed 23017303 5330-01-334-9946

241 Packing, Preformed 23504641 5330-01-336-2997

242 Packing, Preformed 235063 5330-00-454-0370

243 Packing, Preformed 262332 5330-00-443-2045

244 Packing, Preformed 3-916N0552

245 Packing, Preformed 3-924N552-90 5330-01-038-3074

246 Packing, Preformed 52-49529-00 5330-01-348-8331

247 Packing, Preformed A-103 5330-00-115-6327

248 Packing, Preformed A307777000-8 5330-00-920-4157

249 Packing, Preformed ARP568-014 5330-01-213-6795

250 Packing, Preformed FF9446-14

251 Packing, Preformed FF9446-18 5330-01-092-5503

252 Packing, Preformed FF9446-21 5330-01-269-4323

253 Packing, Preformed FF9446-219 5330-00-013-7784

254 Packing, Preformed FF9446-222 5330-00-984-3808

255 Packing, Preformed FF9446-25 5330-01-269-6152

256 Packing, Preformed FF9855-12 5330-01-376-9629
TM 9-2320-364-20-5

F-10 

Section II. MANDATORY REPLACEMENT PARTS LIST (Cont)

(1)

Index No.

(4)

National Stock Number

(3)

Part Number

(2)

Nomenclature

257 Packing, Preformed GG108-NP04-10 4730-01-346-4684

258 Packing, Preformed MS28775-013 5331-00-684-3420

259 Packing, Preformed MS28775-223 5330-00-171-6649

260 Packing, Preformed MS29512-16 5330-00-263-8034

261 Packing, Preformed V75500858 5330-01-350-6007

262 Packing, Preformed VS-1087-4 5330-01-371-5119

263 Packing, Pump Piston P4-4 5330-00-122-0624

264 Pad, Rubber 1946480 5330-01-363-7020

265 Pin, Cotter 0900806-1 5315-00-254-1657

266 Pin, Cotter 126761A 5315-01-157-0960

267 Pin, Cotter 1749HX

268 Pin, Cotter 1840070

269 Pin, Cotter L6451-101 5315-00-187-9591

270 Pin, Cotter MS24665-134 5315-00-839-5820

271 Pin, Cotter MS24665-151 5315-00-815-1405

272 Pin, Cotter MS24665-319 5315-01-267-7570

273 Pin, Cotter MS24665-353 5315-00-839-5822

274 Pin, Cotter MS24665-491 5315-00-059-0206

275 Pin, Cotter MS24665-498 5315-00-849-9854

276 Pin, Cotter MS24665-624 5315-00-059-0217

277 Pin, Cotter MS24665-627 5315-00-013-7508

278 Pin, Cotter XB-T-60 5315-01-204-4893

279 Pin, Roll 1840070

280 Pin, Roll XB-21-S-187-1250 5315-01-448-0604

281 Pin, Roll XB-21-S-312-1250

282 Pin, Roll XB-21-S-312-2500

283 Pin, Roll XB-21-S-500-1000 5315-01-448-0599

284 Pin, Roll XB-S05742

285 Pin, Spring 3145955

286 Plug A-LF-2550 5330-01-276-7351

287 Preformed Packing Kit RN-60-A 4440-01-337-7324

288 Preformed Packing Kit RN-60-V 5330-01-377-2460
TM 9-2320-364-20-5

F-11

Section II. MANDATORY REPLACEMENT PARTS LIST (Cont)

(1)

Index No.

(4)

National Stock Number

(3)

Part Number

(2)

Nomenclature

289 Quick Edge 75000317 2510-01-176-1177

290 Retainer, Packing 8-238N300-90 5330-01-065-5959

291 Rubber Liner 124660A

292 Rubber Strip 70-17-30 9320-00-491-5351

293 Screw 118941A 5305-01-156-5099

294 Screw 1344950 5305-01-155-6107

295 Screw 1778HX 5305-01-133-2114

296 Screw 23512308 5306-01-411-6384

297 Screw 5103642 5305-01-078-1999

298 Screw 59030AX 5305-00-984-6210

299 Screw B71-10015-002 5305-01-352-2066

300 Screw MS35206-267 5305-00-984-6214

301 Screw MS35207-267 5305-00-993-1851

302 Screw MS90725-34 5306-00-225-8499

303 Screw MS90725-60 5305-00-269-3211

304 Screw MS90725-8 5305-00-225-3839

305 Screw SPLE101D05 5306-01-156-8678

306 Screw (Sheet Metal) 1381HX1 5305-01-134-2052

307 Screw Washer Assembly 1756840 5305-01-354-5708

308 Screw Washer Assembly 2050700 5305-01-394-3551

309 Screw, Self-locking 02092 5305-00-696-5115

310 Screw, Self-locking 1367HX1 5305-01-062-1017

311 Screw, Self-locking 23015458 5306-01-363-4057

312 Screw, Self-locking 96-212 5305-01-205-0041

313 Screw, Self-tapping 1324510 5305-01-157-5624

314 Screw, Self-tapping 1345280 5305-01-159-8544

315 Screw, Self-tapping 1354490 5305-01-274-0028

316 Screw, Self-tapping 1723180 5305-01-145-4003

317 Screw, Self-tapping 54067AX 5305-01-150-8714

318 Screw, Tapping 2763HX 5305-01-353-6120

319 Screws, Self-locking 31 WLFS 51618-062 5306-01-350-8223

320 Seal 1862760
TM 9-2320-364-20-5

F-12 

Section II. MANDATORY REPLACEMENT PARTS LIST (Cont)

(1)

Index No.

(4)

National Stock Number

(3)

Part Number

(2)

Nomenclature

321 Seal 1941570 5330-01-363-7019

322 Seal 2282340

323 Seal 2282350

324 Seal 23504641 5330-01-336-2997

325 Seal 3S9643-00 5330-00-246-6380

326 Seal 5104105 5330-01-163-8178

327 Seal 75001366 9390-01-179-4508

328 Seal NE-71A 5330-01-277-5103

329 Seal, Door 75001366 9390-01-179-4508

330 Seal, Plain 5103646 5330-01-088-2740

331 Seal, Preformed 101-2203 5330-01-267-7542

332 Seal, Ring N1205B1666 5330-01-351-7881

333 Seal, Ring N1205C1667 5330-01-350-5385

334 Splice, Conductor 327025 5940-01-368-9579

335 Stem, Valve N-1268 2640-01-354-9424

336 Strip, Nut 128757A 5310-01-157-0894

337 Strip, Rubber 350907 5330-01-156-5266

338 Strip, Rubber 352731 5330-00-114-2073

339 Stud 52-49523-00 5307-01-348-7046

340 Tape, Rubber Adhesive SJ5816 9320-01-299-3332

341 U-joint Kit 5-471X 2520-01-359-8444

342 Valve Core 8500V 2640-00-004-8297

343 Washer 1605640 5310-01-383-7327

344 Washer MS27183-10 5310-00-809-4058

345 Washer MS27183-7 5310-00-809-8544

346 Washer MS27183-8 5310-00-809-8546

347 Washer MS37183-62 5310-01-380-3474

348 Washer V75503675 5310-01-389-2364

349 Washer, Copper 31425BX 2520-01-041-3542

350 Washer, Key TW107 5310-01-014-5136

351 Washer, Plastic 16FW008032 5310-00-988-8820

352 Washer, Rubber 8-325N300-90 5330-00-156-3208
TM 9-2320-364-20-5

F-13/(F-14 blank)

Section II. MANDATORY REPLACEMENT PARTS LIST (Cont)

(1)

Index No.

(4)

National Stock Number

(3)

Part Number

(2)

Nomenclature

353 Washer, Sealing 1760040 5310-01-353-2062

354 Washer, Star 50001716 5310-01-372-6391

TM 9-2320-364-20-5

G-1

APPENDIX G

TOOL IDENTIFICATION LIST

Section I. INTRODUCTION

G-1. SCOPE.

This appendix lists all of the tools needed to repair the truck.

G-2. GENERAL.

This appendix is a list of tools, both common and special, test equipment and tool kits used at unit level to repair the

truck. This list is arranged alphabetically and shows the nomenclature, part number (P/N), National Stock Number

(NSN) and references when applicable. The index number corresponds to the index number found in the task box of

maintenance procedures.

Section II. COMMON TOOLS, TEST EQUIPMENT AND TOOL KITS 

Item

No. Description Part No. NSN Reference

1 Adapter, Torque Wrench J-8932-B 5120-00-019-5232

2 Adapter, Radiator J-29003-A 4910-01-170-4929

3 Analyzer Set, STE/ICE-R 12259266 4910-01-222-6589

4 Bar, Crow 10501985 5120-00-224-1390 SC 4910-95-A74

5 Bar, Wrecking 130 5120-00-293-0665 SC 4910-95-A72-HR

6 Bit, Set 38699-1 5120-01-170-4454 SC 4910-95-A72-HR

7 Caliper, Micrometer, Inside 124B 5120-00-221-1921

8 Cap And Plug Set 10935405 5340-00-450-5718

9 Caps, Vise Jaw GGG-C-137 5120-00-221-1506 SC 4910-95-A74

10 Clamp, Machinist’s GGG-C-406 5120-00-222-1612 SC 4910-95-A72-HR

11 Compressor Unit, Air MIL-C-13874 4130-00-752-9633 SC 4910-95-A72-HR

12 Connector Remover (DEUTSCH) 114010 5120-01-158-4707

13 Crimping Tool J35123 5120-01-355-0844

14 Crimping Tool (Cannon) 995-0001-904 5120-01-374-8937

15 DDEC Repair Kit J-35888 2815-01-355-5993

16 Dispensing Pump FEDXXD370 4930-00-287-8293 SC 4910-95-A72-HR

17 Drill, Electric, Portable WD00661 5130-00-293-1849 SC 4910-95-A74

18 Drill, Electric, Portable, 1/4 in. 1070 5130-00-889-8993 SC 4910-95-A31

19 Drill Set, Twist GGG-D-751 5133-00-293-0983 SC 4910-95-A74

20 Drill Set, Twist GGG-D-751 5133-00-449-6775 SC 3470-95-A02

21 Drum, Storage 57 Gal MIL-D-6054 8110-00-082-2626

22 Extractor Tool, Electrical 901019-3 5120-01-015-2154

23 Extractor Tool, Electrical 305183 5120-01-020-5926

24 Funnel L-F-1593 7240-00-404-9795 SC 4910-95-A74
TM 9-2320-364-20-5

G-2 

Section II. COMMON TOOLS, TEST EQUIPMENT AND TOOL KITS (CONT)

Item

No. Description Part No. NSN Reference

25 Gage, Air Inflation 1506 4910-00-204-2644

26 Gage, Belt Tension (Tensiometer) BT-33-73BF 4935-01-254-9808

27 Gage, Feeler 007958 5210-01-214-2138

28 Gloves, Chemical Oil Protective ZZ-G-381 8415-00-641-4601 SC 4910-95-A74

29 Gloves, Heavy Duty A-A-50022 8415-00-268-7859 SC 4910-95-A72-HR

30 Goggles, Industrial GGG-G-13 4140-00-269-7912 SC 4910-95-A74

31 Gun, Air Blow GGG-G-770 4940-00-333-5541 SC 4910-95-A72-HR

32 Gun, Heat 500 4940-00-561-1002

33 Hammer, Hand Soft Plastic 3-HD 5120-01-065-9037 SC 4910-95-A72-HR

34 Handle, Driver J-3154-1 5120-00-808-5082

35 Handler, Installer J7079-2 5120-01-977-5578

36 Harness, Breakout J34517 6150-01-373-7771

37 Hose, Drain ZZ-H-461 4720-00-356-8557 SC 4910-95-A74

38 Insertion Tool, (Cannon) CIT-SS-10 5120-01-374-8968

39 Installer, Seal J8550 5120-00-977-5579

40 Jack, Hydraulic, Hand 5029209-111-101 5120-00-224-7330 SC 4910-95-A74

41 Jack, Kit, Hydraulic, Hand GGG-J-60 5120-00-587-4144

42 Jackstand, Trestle 306 4910-00-251-8013 SC 4910-95-A74

43 Measure, Liquid MIL-M-43530 7240-00-138-7984

44 Multimeter ANURM105C 6625-00-999-6282 SC 4910-95-A72-HR

45 Multiplier, Torque 292 5120-00-574-9318 SC 4910-95-A72-HR

46 Pan, Drain (6 Gal) MIL-P-45819 4940-00-795-3595

47 Pan, Drain (4 Gal) 450 4940-00-387-9592 SC 4910-95-A74

48 Pliers, Brake Repair 131A 5120-00-690-8044 SC 4910-95-A74

49 Pliers, Retaining Ring 2BH945 5120-01-375-5699

50 Pressure Test Kit 3SK911 4910-01-378-9068

51 Puller Kit, Universal 1677 5180-00-423-1596 SC 4910-95-A73

52 Pulley Kit, Pump, Roof Mount 2HP645 5120-01-375-5700

53 Reader, Diagnostic J38500-1 4910-01-343-3508

54 Removal Tool, Oil Filter 2304 5120-00-865-0933 SC 4910-95-A72-HR

55 Remover, Connector J38384 5120-01-355-3012

56 Repair Tool, Pneumatic Tire, Valve 7471 5120-00-308-3809 SC 4910-95-A74

57 Respirator, Air Filter GGG-M-125/6 4240-00-022-2524 SC 4910-95-A72-HR

58 Rivet Gun 352 5130-00-982-8078

59 Scriber, Machinist’s, 8 To 9 In Long 68A 5120-00-221-7063

60 Socket Set, Deepwell, 1/2 In. GGG-W-641 5120-00-596-8622 SC 4910-95-A72-HR

61 Socket Set, 3/4 In. GGG-W-641 5120-00-204-1999 SC 4910-95-A72-HR

62 Socket Set, 3/8 In. 221FSMY 5120-01-117-3876 SC 4910-95-A72-HR

63 Socket, Wheel Bearing Adj. Nut 

3 1/4 In. 6 Pt. 1908 5120-01-144-5331 SC 4910-95-A74

64 Soldering Kit, Torch LP-999G 3439-00-542-0531 SC 4910-94-A74
TM 9-2320-364-20-5

G-3/(G-4 blank)

Section II. COMMON TOOLS, TEST EQUIPMENT AND TOOL KITS (CONT)

Item

No. Description Part No. NSN Reference

65 Strainer Tool FC 88A 5120-01-328-2504

66 Tape, Measurer GGG-T-106 5120-01-554-7085 SC 4910-95-A72-HR

67 Terminal Crimper J35688 5120-01-355-0845

68 Terminal Remover J33095 5120-01-353-2534

69 Terminal Remover J35689-A 5120-01-357-2937

70 Terminal Remover, Weatherpac J36400-5 5120-01-374-8969

71 Tester, Pressure, Radiator J24460-01 4910-01-170-4928

72 Tool Kit, Blind Rivet D-100-MIL-1 5180-01-201-4978 SC 4910-95-A74

73 Tool Kit, Electric 7550526 5180-00-876-9336 SC 4910-95-A72-HR

74 Tool Kit, General Mechanic’s: 

Automotive SC-5180-90-N26 5180-00-177-7033 SC 5180-90-N26

75 Vise, Machinist’s 504M2 5120-00-293-1439 SC 4910-95-A74

76 Weatherpac Crimper J38852 5120-01-374-8936

77 Wrench, Box 1/2 In. J4242 5120-00-591-2685

78 Wrench, Combination 1 1/16 In. 1234 5120-00-228-9515 SC 4910-95-A74

79 Wrench, Combination 1 1/8 In. 1172 5120-00-228-9516 SC 4910-95-A74

80 Wrench, Combination 1 1/4 In. 1173 5120-00-228-9517 SC 4910-95-A74

81 Wrench, Combination 1 5/16 In. 1174 5120-00-228-9518 SC 4910-95-A74

82 Wrench, Combination 1 3/8 In. 1176A 5120-00-228-9519 SC 4910-95-A74

83 Wrench, Combination 1 1/2 In. 1178 5120-00-277-8834 SC 4910-95-A74

84 Wrench, Combination 1 5/8 In. 1180 5120-01-016-7144

85 Wrench, Combination 1 11/16 In. A-A-1351 5120-00-184-8566

86 Wrench, Combination 1 3/4 In. 1256 5120-00-020-8658

87 Wrench, Combination 1 7/8 In. 1260 5120-00-020-8632

88 Wrench, Combination 2 In. 1190 5120-00-957-3115

89 Wrench, Combination 2 1/8 In. 1268 5120-00-203-4795

90 Wrench, Crowfoot 1/2 In., 3/8 In

Drive FRH-1605 5120-01-114-4933 SC 4910-95-A74

91 Wrench, Pipe 3 1/2 In. Opening GGG-W-651 5120-00-277-1485

92 Wrench, Set, Combination GGG-W-00645 5120-00-895-9566 SC 4910-95-CL-A74

93 Wrench Set, Socket 3/8 In. Drive 51200017510 5120-00-322-6231 SC 4910-95-A31

94 Wrench, Spanner 2HS129 5120-01-375-4502

95 Wrench, Torque (0 To 175 Lb-Ft

[0–237 N.

M]) 1753LDF 5120-00-640-6364 SC 4910-95-A74

96 Wrench, Torque (0 To 300 Lb-Ft

[0–407 N.

M]) 6134A 5120-00-555-1523 SC 4910-95-A72-HR

97 Wrench, Torque (0 To 600 Lb-Ft

[0–814 N.

M]) SW130-301 5120-00-221-7983 SC 4910-95-A31

98 Wrench, Torque, 3/8 In. Drive (0 To

60 N.M ) TESI60 5120-01-112-9531 SC 4910-95-A72-HR

99 Zonal Separator, Oil And Water

Spray Gun MIL-S-12928CLASS1 4940-00-242-4100 SC 4910-95-A73

TM 9-2320-364-20-5

 INDEX-1

INDEX

Subject, Para

A

Accessory Items Introduction, 19-1

Accumulator, Crane, Replacement, 18-10

Adapter, Engine Oil Filter, Repair, 3-8

Adapter, Power Take-Off (PTO), Replacement, 3-3

After Cooler Repair, 12-22

After Cooler, Air Dryer/, Replacement, 12-20

Air Bag, Axle No. 3, Troubleshooting, 2-25

Air Box Pressure Transducer Replacement, 7-77

Air Box, Fresh, Replacement, 19-16

Air Chamber

Axle No. 1 and 2, Replacement, 12-9

Axle No. 3, 4 and 5, Replacement, 12-10

Transfer Case Differential, Replacement, 9-3

Air Cleaner

Assembly Repair, 4-4

Mounting Bracket Grab Handle Replacement, 4-6

Pressure Transducer Replacement, 7-75

Skirt Replacement, 17-16

Air Cylinder and Rotary Paddle, CHU, Replacement/

Adjustment, 21-43

Air Dryer

After Cooler, Replacement, 12-20

Bracket, Replacement, 15-7

Coelescing Filter Replacement, 12-24

Guard Replacement, 12-19

Repair, 12-21

Reservoir Replacement, 12-35

Air Filter Replacement, 4-5

Air Governor & Bracket, Replacement/Adjustment,

12-41

Air Horn Replacement, 19-10

Air Horn Valve Replacement, 19-11

Air Intake Ducting Replacement, 4-7

Air Line Replacement, 12-36

Air Manifold (Cab) Replacement, 12-25

Air Manifold/Air Regulator/Pressure Protection

Valve Assembly Repair, 12-38

Air Pressure Indicator Replacement, 23-2

Air Regulator, Cab, Windshield Washer,

Replacement, 12-26

Air Regulator, Air Manifold/, /Pressure Protection Valve

Assembly Repair, 12-38

Air Reservoir

No. 1 Replacement, 12-27

No. 2 Replacement, 12-28

No. 3 Replacement, 12-29

Subject, Para

A (CONT).

Air Reservoir (continued)

No. 4 Replacement, 12-30

No. 5 Replacement, 12-31

Air Restriction Indicator Replacement, 23-3

Air System Troubleshooting, 2-27

Air-to-Oil Cooler Replacement, 20-4

Air Valve, CHU, Replacement, 21-42

Alternator

Belts Replacement/Adjustment (145 Amp), 7-4

Belts Replacement/Adjustment (200 Amp), 7-5

Replacement (145 Amp), 7-2

Replacement (200 Amp), 7-3

Amber Marker Light Replacement, 7-54

Angled Roller Replacement, 15-16

Arctic Kit

Battery Box Replacement, 21-5

Battery Disconnection/Connection, 21-11

Battery Replacement, 21-4

Jumperwire Harness Replacement, 21-9

Relays Replacement, 21-2

Switch Wire Harness Replacement, 21-10

Water Pump Replacement, 21-6

Waterjacket Replacement, 21-7

Wire Harness Replacement, 21-8

Arctic Pump

Switch Replacement, 21-3

Troubleshooting, 2-36

Arm Assembly, CHU Slider, Repair, 21-31

Arm, Wiper, Replacement, 19-5

Armament Maintenance Introduction, 22-1

ATEC Troubleshooting, 2-15

Auxiliary Fuel Tank and Brackets Replacement,

4-9

Auxiliary Fuel Tank Tread Platform Assembly

Replacement, 15-24

Auxiliary Hand Pump Repair, 18-9

Axle

Brake Drum Replacement, 13-3

Breather Elbow Replacement, 11-3

Maintenance Introduction, 11-1

No. 1 and 2 Air Chamber Replacement, 12-9

No. 1, 2 and 5 Tie-Rod Repair, 14-11

No. 1, 2 and 5 CTIS Spindle Fittings Replacement,

 13-4

No. 1, 2 and 5 Pivot and Spindle Inspection, 11-4
TM 9-2320-364-20-5

INDEX-2 

Subject, Para

A (CONT).

Axle (continued)

No. 1 Locking Cylinder Lines and Fittings

 Replacement, 11-5

No. 2 Locking Cylinder Lines and Fittings

 Replacement, 11-6

No. 3 Air Bag Troubleshooting, 2-37

No. 3 and 4 CTIS Spindle Fittings Replacement,

 13-5

No. 3, 4 and 5 Air Chamber Replacement, 12-10

No. 3 Locking Cylinder Lines and Fittings

 Replacement, 11-7

No. 4 Locking Cylinder Lines and Fittings

 Replacement, 11-8

No. 5 Locking Cylinder Lines and Fittings

 Replacement, 11-9

No. 5 Steering Shaft Repair, 14-10

Oil Service, 11-2

Stop Replacement, 15-12

Troubleshooting, 2-33

B

Baffle, Right Hand, Replacement, 17-18

Ball Valve Replacement, 12-12

Battery

Arctic Kit, Disconnection/Connection, 21-11

Arctic Kit, Replacement, 21-4

Box and Shunt Repair, 7-89

Box Wiring Replacement (145 AMP), 7-90

Box Wiring Replacement (200 AMP), 7-91

Box, Arctic Kit, Replacement, 21-5

Disconnection/Connection, 7-87

Disconnect Switch Box Repair, 7-106

Gage Replacement, 7-22

Replacement, 7-88

Beacon Bracket Replacement, 19-9

Belt, Seat, Replacement, 17-44

Belts

Alternator, Replacement/Adjustment 

 (145 AMP), 7-4

Alternator, Replacement/Adjustment 

 (200 AMP), 7-5

Blackout Light Repair, 7-51

Blade, Wiper, Replacement, 19-6

Blower, Heater, Motor Replacement, 19-13

Body, Cab and, Maintenance Introduction, 17-1

Boom Sheave Replacement, 18-2

Boom Wear Pads Inspection/Replacement, 18-3

Subject, Para

B (CONT).

Bracket

Beacon, Replacement, 19-9

Decontamination Kit, Replacement, 24-3

Diagnostic Request Switch, Replacement,

 DDEC III, 7-28

First Aid Kit, Replacement, 17-56

Rear Composite Light and, Repair, 7-47

Rifle Stowage, Replacement, 17-57

Stowage Box and, Replacement, 17-54

Brackets, 

Auxiliary Fuel Tank and, Replacement, 4-9

CHU Front Support, Replacement, 21-46

Main Fuel Tank and, Replacement, 4-8

Brake

Axle, Drum, Replacement, 13-3

Maintenance Introduction, 12-1

Pressure Switch Replacement, 12-5

Shoe/Self-Adjuster Repair, 12-2

Shoe Adjustment, 12-3

System Troubleshooting, 2-24

Treadle Valve Replacement, 12-4

Breather

Axle, Elbow, Replacement, 11-3

Hydraulic Reservoir Filler, Replacement, 20-14

Transfer Case, Replacement, 9-8

Transmission, Replacement/Service, 8-5

Bumper Stop Bracket, 15-18

Bumper Weldment Support, CHU, Replacement, 21-41

Bushing, Shock Absorber and, Replacement, 16-2

Button

Horn, Replacement, 14-4

Safe Lowering, Replacement, 7-41

Buzzer, Warning, Replacement, 7-25

C

Cab Air Regulator, Windshield Washer, 

Replacement, 12-26

Cab and Body Maintenance Introduction, 17-1

Cab Dome Light Assembly Replacement, 7-49

Cab Door

Adjustment, 17-7

and Hinge Replacement, 17-8

Repair, 17-9

Cab Engine Access Panel Replacement, 17-24

Cab Fender Edging Replacement, 17-2

Cab Floor Drain Plug Replacement, 17-48

Cab Insulation Replacement, 17-19
TM 9-2320-364-20-5

 INDEX-3

Subject, Para

C (CONT).

Cab Seat

Lock Alignment Procedure, 17-41

Repair, 17-40

Support Replacement, 17-42

Cab Step Replacement, 15-5

Cable

Crane Hoist, Replacement, 18-5

Self-Recovery Winch (SRW), Replacement, 18-17

Slave Connector and, Replacement, 7-99

Transfer Case Shift, Adjustment, 9-5

Transfer Case Shift, Replacement, 9-6

Cargo Net Replacement, 17-43

Center Mud Flap Replacement, 17-38

Central Tire Inflation System (CTIS) 

Controller Protection Kit Installation/Replacement,

 13-13

Troubleshooting, 2-26

Chemical, Biological, Radiological (CBR) 

Introduction, 24-1

Circuit Breaker Replacement, 7-16

Cleaner, Air, Assembly, Replacement, 4-4

Clevis, Crane Hook Block, & Hook, Repair, 18-8

Coalescing Filter Assembly Replacement, 12-23

Cold Plate, DDEC II Engine, Electronic Control Module 

(ECM), Replacement, 7-56

Cold Plate, DDEC III Engine, Electronic Control

Module (ECM), Replacement, 7-57

Common Tools and Equipment, 2-1

Connector Bracket, Truck-to-Trailer LHS Electrical,

 Replacement, 15-19

Container Guide, CHU, Repair, 21-28

Container Handling Unit (CHU)

Air Cylinder and Rotary Paddle Replacement/

 Adjustment, 21-43

Air Valve Replacement, 21-42

Bumper Weldment Support Replacement, 21-41

Container Guide Repair, 21-28

Control Box Assembly Replacement, 21-21

Control Box Repair, 21-23

Control Box Wiring Replacement, 21-22

Deck Weldment Replacement, 21-40

Front Crossmember Assembly Replacement, 21-45

Front Support Brackets Replacement, 21-46

Jumperwire Harness Replacement, 21-19

Lifting Frame Assembly Replacement, 21-35

Lifting Frame Flipper Bracket and Lock Plate Repair,

 21-38

Lifting Frame Locking Plate Assembly Replacement,

 21-36

Subject, Para

C (CONT).

Container Handling Unit (CHU) (continued)

Lifting Frame Lower Container Lock Plate Repair,

 21-37

Lifting Frame Strap Replacement, 21-47

Light Bar and Brackets Assembly Repair, 21-27

Long Strut Bracket Assembly Repair, 21-33

Mode Switch Replacement/Adjustment, 21-25

Proximity Switch and Sensing Plate Replacement/

 Adjustment (Hook Arm Up), 21-24

Rear Bracket Assembly Replacement, 21-32

Rear Lock Limit Switch Replacement/Adjustment,

 21-26

Self-Recovery Winch (SRW), Rear Guide

 Replacement, 21-39

Short Strut and Pin Bracket Assembly Repair,

 21-30

Slider Arm Assembly Repair, 21-31

Slider/Pivot Assembly Repair, 21-29

Stow Cone Weldment Replacement, 21-44

Stow Weldment Replacement, 21-34

Troubleshooting, 2-38

Wire Harness Replacement, 21-20

Control Assembly, LHS (Cab), Replacement, 7-40

Control Box

Assembly, CHU Replacement, 21-21

CHU, Repair, 21-23

Crane Remote, Repair, 18-4

Electronic, Replacement, 17-23

Electronic Cover, Replacement, 17-22

Electronic Right Side Panel, Replacement, 17-21

Electronic Side Panel, Replacement, 17-20

Wiring, CHU, Replacement, 21-22

Control, Polarity Protection, Replacement 

(200 AMP), 7-11

Control, Vernier, Replacement, 7-100

Coolant Level Sight Glass Replacement, 6-6

Cooling System 

Assembly Replacement, 6-3

Hoses and Tubes Replacement, 6-8

Maintenance Introduction, 6-1

Pressure Test, 6-2

Service, 6-4

Skirt Replacement, 17-17

Troubleshooting, 2-18

Core, Heater, Replacement, 19-14

Coupler, Self-Guided, Repair, 15-20

Cover, Heater Compartment Front, Replacement, 17-5
TM 9-2320-364-20-5

INDEX-4 

Subject, Para

C (CONT).

Crane

Accumulator Replacement, 18-10

Angle Indicator Replacement, 18-7

Hoist Cable Replacement, 18-5

Hook Block, Hook & Clevis Repair, 18-8

Hydraulic Hoses, Tubes and Fittings

 Replacement, 18-11

On/Off and High Idle Switch Replacement, 7-36

Remote Control Box Repair, 18-4

Stowage Box Repair, 17-55

Troubleshooting, 2-29

Winch, LHS Maintenance Introduction, 18-1

Crossmember Assembly, CHU Front Replacement,

21-45

Crossmember, Skid Plate, Replacement, 15-4

CTIS

Air Line Replacement, 13-6

Controller Protection Kit Installation/Replacement,

 13-13

Controller Replacement, 13-7

Front and Rear Manifold Repair, 13-10

Front Manifold Replacement, 13-8

Rear Manifold Replacement, 13-9

Troubleshooting, 2-26

Wheel Valve Replacement, 13-11

D

Dash Manifold Valve Replacement, 12-37

Data Plate Replacement, 19-20

Davit, Spare Tire Carrier and, Replacement, 15-21

DDEC

Coolant Temperature Sensor Replacement, 

 DDEC III, 7-69

Diagnostic Request Switch and Bracket 

 Replacement, DDEC III, 7-28

Engine Oil Pressure Sensor Replacement,

 DDECII, 7-67

Engine Oil Pessure Sensor Replacement,

 DDEC III, 7-68

Oil Temperature Sensor Replacement, 7-70

Troubleshooting, 2-26

Turbo Boost Sensor, 7-63

Decontamination Kit Bracket Replacement, 24-3

Defroster Plenum Replacement, 17-3

Defroster, Heater/, Tubing Replacement, 19-19

Destruction Of Army Material To Prevent 

Enemy Use, 1-3

Subject, Para

D (CONT).

Diagnostic Request Switch and Bracket

Replacement, DDEC III, 7-28

Differential Pressure Switch Replacement, 7-84

Disconnection/Connection, Battery, 7-87

Disconnect Switch Box, Battery, Repair, 7-106

Door

Cab, Adjustment, 17-7

Cab, and Hinge Replacement, 17-8

Cab, Repair, 17-9

Drain/Fill (Service)

Axle Oil, 11-2

Cooling System, 6-4

Engine Oil, 3-2

Fuel/Water Separator, 4-15

Main Hydraulic Reservoir, 20-11

Steering System, 14-2

Transfer Case, 9-2

Transmission Oil, 8-3

Driveshaft

and U-Joint Repair, 10-2

Main Hydraulic Pump, Repair, 20-2

Maintenance Introduction, 10-1

Troubleshooting, 2-23

DUVAC (Dual Voltage Alternator Control)

Adjustment (145 AMP), 7-10

Replacement (145 AMP), 7-9

E

ECM, DDEC II Engine Cold Plate/, 

Replacement, 7-56

ECM, DDEC III Engine Cold Plate/,

Replacement, 7-57

ECU, Transmission, Replacement, 7-71

Electric

Gage Replacement, 7-21

Horn Replacement, 7-85

Resistor Replacement, 7-96

Electrical System

Maintenance Introduction, 7-1

Troubleshooting, 2-20

Electronic Control Box (ECB)

Cover Replacement, 17-22

Replacement, 17-23

Right Side Panel Replacement, 17-21

Side Panel Replacement, 17-20
TM 9-2320-364-20-5

 INDEX-5

Subject, Para

E (CONT).

Emergency Air Quick Disconnect Replacement, 12-42

Emergency Gladhand Bracket Replacement, 12-44

Emergency Steering Switch Replacement, 7-105

Engine Brake Wire Harness Replacement, 7-102

Engine Cold Plate/Electronic Control Module 

(ECM) Replacement, DDEC II, 7-56

Engine Cold Plate/Electronic Control Module (ECM)

Replacement, DDEC III, 7-57

Engine Cover

Engine Panel, Assembly, Replacement, 17-10

Grab Handle Replacement, 17-13

Latch Replacement, 17-12

Latch/Stowage Box, Adjustment 17-60

Rubber Replacement, 17-11

Engine Maintenance Introduction, 3-1

Engine Oil

Filter Adapter Cover Repair, 3-8

Filter Replacement, 3-6

Pressure Sending Unit Replacement, 7-79

Pressure Sensor, DDEC II, Replacement, 7-67

Pressure Sensor, DDEC III, Replacement 7-68

Pressure Switches, Replacement, 7-60

Remote, Filter Manifold Replacement, 3-9

Remote, Filter Replacement, 3-7

Service, 3-2

Temperature Sensor, STE/ICE, Replacement, 7-66

Engine Panel and Cover Assembly Replacement, 17-10

Engine Switch Replacement, 7-32

Engine Troubleshooting, 2-16

Engine, Cab Access Panel, Replacement, 17-24

Engine/Transmission Hose Replacement, 3-10

Equipment Characteristics, Capabilities, 

And Features, 1-7

Equipment Data, 1-9

Ether Start Aid

Assembly Replacement, 4-18

Hose and Fittings Replacement, 4-19

Switch Replacement, 7-33

Thermostat Replacement, 4-20

Exhaust

Muffler Replacement, 5-2

Pipes Replacement, 5-3

System Maintenance Introduction, 5-1

Troubleshooting, 2-31

Subject, Para

F

Fan Control Solenoid Valve Replacement, 20-5

Fender

Left Front, and Rear Skirt, Replacement, 17-34

Rear, and Fender Support Arm, Replacement, 17-35

Right Front, and Rear Skirt, Replacement, 17-33

Filler Breather, Hydraulic Reservoir Replacement,

20-14

Filter

Air, Replacement, 4-5

Air Dryer Coelescing, Replacement, 12-24

Engine Oil, Adapter Cover Repair, 3-8

Engine Oil, Replacement, 3-6

Fuel/Water Separator, Replacement, 4-17

Gas Particulate Unit Kit, Mounting/Installation, 24-2

High Pressure Hydraulic, Replacement, 20-6

High Pressure Hydraulic Head, Repair, 20-8

High Pressure Hydraulic Head, Assembly 

 Replacement, 20-7

Main Hydraulic, Replacement, 20-9

Main Hydraulic Reservoir, Assembly Replacement,

 20-10

Remote Engine Oil, Manifold Replacement, 3-9

Remote Engine Oil, Replacement, 3-7

Secondary Fuel, Head, Replacement, 4-14

Secondary Fuel, Replacement, 4-13

Steering, Replacement, 14-16

Steering, Adapter Head, Replacement, 14-17

Fire Extinguisher Mount Replacement, 17-6

First Aid Kit Bracket Replacement, 17-56

Fittings

Axles No. 1, 2 and 5 CTIS Spindle, Replacement,

 13-4

Axles No. 3 and 4 CTIS Spindle, Replacement, 13-5

Flasher Unit, Replacement, 7-97

Fluid Level Gage, Hydraulic, Replacement, 20-15

Foot Rest Repair, 17-47

Frame

Assembly, CHU Lifting, Replacement, 21-35

Flipper Bracket and Lock Plate, CHU Lifting, Repair,

 21-38

Locking Plate Assembly, CHU Lifting, Replacement,

 21-36

Lower Container Lock Plate, CHU Lifting, Repair

 21-37

Maintenance Introduction, 15-1

Strap, CHU, Replacement, 21-47
TM 9-2320-364-20-5

INDEX-6 

Subject, Para

F (CONT).

Fresh Air Box Replacement, 19-16

Front Composite Light Repair, 7-46

Front Crossmember Assembly, CHU, Replacement,

 21-45

Front Double Check Valve Replacement, 12-11

Front Gladhand Bracket Replacement, 12-32

Front Marker Light Assembly Repair, 7-52

Front Support Brackets, CHU, Replacement, 21-46

Front Support, Machine Gun Ring, Replacement, 22-4

Front Tandem Crossmember Torquing Procedure,

 15-6

Fuel

Auxiliary, Tank and Brackets Replacement, 4-9

Auxiliary, Tank Tread Platform Assembly

 Replacement, 15-24

Filter Pressure Transducer Replacement, 7-78

Hoses and Tubes Replacement, 4-12

Level Sending Unit Replacement, 4-11

Main, Tank and Brackets Replacement, 4-8

Pressure Transducer Replacement, 7-74

Priming Pump Filter Replacement, 4-3

Priming Pump Replacement, 4-2

Shutoff Valve Replacement, 4-10

System Maintenance Introduction, 4-1

System Troubleshooting, 2-29

Temperature Sensor Replacement, 7-62

Fuel/Water Separator

and Bracket Replacement, 4-16

Filter Replacement, 4-17

Service, 4-15

G

Gage

Battery, Replacement, 7-22

Electric, Replacement, 7-21

Hydraulic Fluid Level, Replacement, 20-15

Wiring Harness, Instrument Panel, Replacement,

 7-14

Gages (Non-electrical) Introduction, 23-1

Gas Particulate Filter Unit Kit, 

Mounting/Installation, 24-2

Gasket

Left Rocker Cover and, Replacement, 3-4

Right Rocker Cover and, Replacement, 3-5

Gear Box

90 Degree, Replacement, 14-13

Steering Shaft, Repair, 14-9

Subject, Para

G (CONT).

General Instructions

Assembly, 2-46

Cleaning, 2-43

Disassembly, 2-42

Inspection, 2-44

Installation, 2-47

Removal, 2-41

Repair, 2-45

General Maintenance Procedures, 2-8

General Wire Harness Repair, 7-101

Gladhand Replacement, 12-43

Glove Box Grab Handle Replacement, 17-50

Glove Box Replacement, 17-53

Grab Handle

Air Cleaner Mounting Bracket, Replacement, 4-6

Engine Cover, Replacement, 17-13

Glove Box, Replacement, 17-50

Heater Control Side Panel, Replacement, 17-49

Instrument Panel, Replacement, 17-51

Side Cab, Replacement, 17-52

Grille, Radiator, Assembly, Replacement, 17-14

Grille Skins, Right, Left and Rear, Replacement, 17-15

Ground Handling, 2-40

Guard, Window, Replacement, 17-46

Guide, Self-Recovery Winch (SRW)

Front Tension, Repair, 18-13

Front, Replacement, 18-14

Rear Tension, Repair, 18-15

Rear, Replacement, 18-16

H

Hand Brake

Switch Replacement, 12-8

Valve Replacement, 12-46

Hand Held Work Lamp Assembly Repair, 7-55

Hand Pump, Auxiliary, Repair, 18-9

Hand Receipt Manual and Inventory of Equipment, 2-5

Hard Lift Assembly, Rear, Replacement, 15-8

Harness, CHU Jumperwire, Replacement, 21-19

Hatch Ring, Machine Gun, Replacement, 22-6

Hazard Switch, Replacement, 7-35

Head, High Pressure Hydraulic Filter, Repair, 20-8

Head Assembly, High Pressure Hydraulic Filter,

Replacement, 20-7

Head Light Adjustment, 7-44

Head Light Assembly Replacement, 7-45
TM 9-2320-364-20-5

 INDEX-7

Subject, Para

H (CONT).

Heater

Assembly Replacement, 19-12

Blower Motor Replacement, 19-13

Compartment Access Panel Replacement, 17-4

Compartment Front Cover Replacement, 17-5

Control Panel Repair, 19-17

Control Side Panel Grab Handle Replacement, 17-49

Control Valve Replacement, 19-18

Core Replacement, 19-14

Defroster Tubing Replacement, 19-19

Hoses and Fittings Replacement, 19-15

High Pressure Hydraulic Filter

Head Assembly Replacement, 20-7

Head Repair, 20-8

Replacement, 20-6

Hoist, Crane Cable, Replacement, 18-5

Hook, Crane, Block, Hook & Clevis Repair, 18-8

Horizontal Roller Replacement, 15-15

Horn

Button Replacement, 14-4

Electric, Replacement, 7-85

Hoses, Lines, and Fittings

Air, Replacement, 12-36

Heater, Replacement, 19-15

Hose and Fittings, Ether Start Aid, 

 Replacement, 4-19

Hose, Engine/Transmission, Replacement, 3-10

Hose, Transfer Case, Replacement, 9-7

Hoses and Tubes, Cooling System, Replacement, 6-8

Hoses and Tubes, Fuel, Replacement, 4-12

Main Hydraulic, Replacement, 20-3

Steering Hydraulic, Replacement, 14-14

Hydraulic

Drain Hose Kit Installation, 20-16

Fluid Level Gage Replacement, 20-15

Reservoir Filler Breather Replacement, 20-14

Reservoir Strainer Replacement, 20-13

Selector Switch Replacement, 7-31

System Maintenance, Introduction, 20-1

System Troubleshooting, 2-31

I

Idler Shaft, Windshield Wiper, Replacement, 19-7

Introduction to Logic Tree Troubleshooting, 2-25

Indicator

Air Pressure, Replacement, 23-2

Air Restriction, Replacement, 23-3

Crane Angle, Replacement, 18-7

Subject, Para

I (CONT).

Instrument Panel

Gage Wiring Harness Replacement, 7-14

Grab Handle Replacement, 17-51

Replacement, 7-13

Switch Wiring Harness Replacement, 7-15

Insulation, Cab, Replacement, 17-19

Intake Ducting, Air, Replacement, 4-7

Interface

Auxiliary Hydraulic Valve Replacement, 21-17

Manual Override Solenoid Valve Replacement,

 21-18

Mounting Bracket Replacement, 21-13

Powerbox Assembly Repair, 21-15

Powerbox Wiring Replacement, 21-16

Quick Disconnect Assembly Replacement, 21-12

Troubleshooting, 2-37

Wiring Harness Replacement, 21-14

Isolator Replacement (145 AMP), 7-34

J

Jumperwire Harness, Arctic Kit, Replacement, 21-9

Jumperwire Harness, CHU, Replacement, 21-19

L

Ladder Support Repair, 17-58

Lamp

Hand Held Work, Assembly, Repair, 7-55

Warning, Replacement, 7-24

Left

Fender Front and Rear Skirt Replacement, 17-34

Front Mud Flap Replacement, 17-36

Front Noise Panel Replacement, 17-27

Rocker Cover and Gasket Replacement, 3-4

Side Noise Panel Replacement, 17-28

LHS (Load Handling System)

Control Assembly (Cab) Replacement, 7-40

Crane, Winch Maintenance Introduction, 18-1

Electrical Connector Bracket, Truck-to-Trailer,

 Replacement, 15-19

Junction Box Replacement, 7-42

Troubleshooting, 2-28

Lifting Frame

Assembly, CHU, Replacement, 21-35

Flipper Bracket and Lock Plate, CHU, Repair, 21-38

Locking Plate Assembly, CHU, Replacement, 21-36

Lower Container Lock Plate, CHU, Repair, 21-37

Strap, CHU, Replacement, 21-47
TM 9-2320-364-20-5

INDEX-8 

Subject, Para

L (CONT).

Light

Amber Marker, Replacement, 7-54

Assembly, Rear Marker, Repair, 7-53

Assembly, Front Marker, Repair, 7-52

Bar and Bracket, CHU, Repair, 21-27

Blackout, Repair, 7-51

Cab Dome, Assembly, Replacement, 7-49

Front Composite, Repair, 7-46

Panel, Replacement, 7-23

Rear Composite, and Bracket, Repair, 7-47

Rear Fender Side Marker, Replacement, 7-48

Reverse, Repair, 7-50

Lines, Air, CTIS, Replacement, 13-6

Lines, Air, Replacement, 12-36

Lines/Fittings

No. 1 Axle Locking Cylinder, Replacement, 11-5

No. 2 Axle Locking Cylinder, Replacement, 11-6

No. 3 Axle Locking Cylinder, Replacement, 11-7

No. 4 Axle Locking Cylinder, Replacement, 11-8

No. 5 Axle Locking Cylinder, Replacement, 11-9

Load Sensing Valve Adjustment, 12-34

Load Sensing Valve Replacement, 12-33

Location And Description Of Major Components, 1-8

Lock, Steering, Replacement, 14-7

Locking Cylinder

Lines/Fittings, No. 1 Axle, Replacement, 11-5

Lines/Fittings, No. 2 Axle, Replacement, 11-6

Lines/Fittings, No. 3 Axle, Replacement, 11-7

Lines/Fittings, No. 4 Axle, Replacement, 11-8

Lines/Fittings, No. 5 Axle, Replacement, 11-9

Long Strut Bracket Assembly, CHU, Repair, 21-33

Low Air Switch Replacement, 12-6

M

Machine Gun

Hatch Ring Replacement, 22-6

Platform, Installation/Storage, 22-5

Ring Front Support Replacement, 22-4

Ring Rear Support Replacement, 22-3

Ring Replacement, 22-2

Magnetic Speed Sensor Replacement, 7-72

Magnetic Switch

12 Volt, Replacement, 7-92

24 Volt, Replacement, 7-94

24 Volt Side Panel, Replacement, 7-93

Subject, Para

M (CONT).

Main Hydraulic

Filter Replacement, 20-9

Hoses Replacement, 20-3

Pump Driveshaft Repair, 20-2

Reservoir Filter Assembly Replacement, 20-10

Reservoir Replacement, 20-12

Reservoir Service, 20-11

Maintenance Forms, Records, and Reports, 1-2

Maintenance Introduction, 2-39

Manifold

Air (Cab), Replacement, 12-25

Air, Air Regulator/Pressure Protection 

 Valve Assembly Repair, 12-38

CTIS Front and Rear, Repair, 13-10

CTIS Front, Replacement, 13-8

CTIS Rear, Replacement, 13-9

Remote Engine Oil Filter, Replacement, 3-9

Manual Override Solenoid Valve, Interface,

Replacement, 21-18

Material Handling Crane (MHC), Self-Recovery Winch

(SRW) and Load Handling System (LHS) Maintenance

 Introduction, 18-1

Mirror Assembly Repair, 19-3

Mode Switch, CHU, Replacement/Adjustment, 21-25

Motor

Heater Blower, Replacement, 19-13

Windshield Wiper, Replacement, 19-4

Mount, Fire Extinguisher, Replacement, 17-6

Mounts, Shock Absorber, Replacement, 16-3

Mud Flap

Center, Replacement, 17-38

Left Front, Replacement, 17-36

Rear Splash Guard/Reflector/Spring Bar

 Replacement, 17-39

Right Front, Replacement, 17-37

Muffler Replacement, 5-2

N

90 Degree Gear Box Replacement, 14-13

Net, Cargo, Replacement, 17-43

Noise Panel

Left Front, Replacement, 17-27

Left Side, Replacement, 17-28

Rear, Replacement, 17-29

Rear, Rubber Replacement, 17-30

Right Side, Replacement, 17-26
TM 9-2320-364-20-5

 INDEX-9

Subject, Para

O

Odometer (KM) Replacement, 7-18

Official Nomenclature, Names, and Designations, 1-4

Oil Filter, Transmission, (External), Replacement, 8-4

Oil Pressure Sensor, DDEC II Engine, 

Replacement, 7-67

Oil Pressure Sensor, DDEC III Engine, 

Replacement, 7-68

Oil Pressure Switches, Engine, Replacement, 7-60

Oil Temperature Sensor Replacement, DDEC, 7-70

Outrigger Pads Repair, 18-18

Outrigger Proximity Switch Replacement, 7-43

P

Paddle, CHU Air Cylinder and Rotary, Replacement/

Adjustment, 21-43

Pads, Outrigger, Repair, 18-18

Panel

Cab Engine Access, Replacement, 17-24

Engine, and Cover Assembly Replacement, 17-10

Electronic Control Box (ECB) Side, 

 Replacement, 17-20

Electronic Control Box (ECB) Right Side,

 Replacement, 17-21

Heater Compartment Access, Replacement, 17-4

Heater Control, Replacement, 19-17

Left Front Noise, Replacement, 17-27

Left Side Noise, Replacement, 17-28

Light Replacement, 7-23

Rear Noise, Replacement, 17-29

Rear Noise, Rubber Replacement, 17-30

Right Side Noise, Replacement, 17-26

Parking Brake Switch Replacement, 12-7

Peep Window Replacement, 17-31

Pin Bracket Assembly, CHU Short Strut and,

 Repair, 21-30

Pipes, Exhaust, Replacement, 5-3

Pivot and Spindle, Axle No. 1, 2 and 5, Inspection, 11-4

Pivot Assembly, CHU Slider/, Repair, 21-29

Plate

Data, Replacement, 19-20

Roof Cover, Replacement, 17-25

Skid, Crossmember Replacement, 15-4

Skid, Structure Replacement, 15-3

Skid, Replacement, 15-2

Subject, Para

P (CONT).

Platform, Machine Gun, Installation/Storage, 22-5

Platform Assembly Replacement (Model 1075 only),

15-10

Plenum, Defroster, Replacement, 17-3

Polarity Protection Control Replacement (200 AMP),

7-11

Power Take-Off (PTO) Adapter Replacement, 3-3

Preparation For Storage or Shipment, 2-55

Preparation For Storage or Shipment Introduction, 2-48

Pressure Protection Valve Assembly, Air Manifold/

Air Regulator Replacement, 12-38

Pressure Test, Cooling System, 6-2

Preventive Maintenance Checks and Services (PMCS)

Introduction, 2-7

Tables, 2-9

Priming Pump Filter, Fuel, Replacement, 4-3

Priming Pump, Fuel, Replacement, 4-2

Principles of Operation

Air System, 1-13

Cab, 1-21

Central Tire Inflation System (CTIS), 1-20

Electrical System, 1-12

Engine Systems, 1-11

Hydraulic System, 1-14

Load Handling System (LHS), 1-18

Material Handling Crane (MHC), 1-17

PLS Flatrack (FR), 1-23

PLS Trailer (PLST), 1-22

Power Train, 1-10

Self-Recovery Winch (SRW), 1-16

Steering System, 1-15

Wheels And Tires, 1-19

Proximity Switch

Hookarm Down, Replacement/Adjustment, 7-37

Hookarm Up, CHU, and Sensing Plate

 Replacement/Adjustment, 21-24

Hookarm Up, Replacement/Adjustment, 7-38

Mainframe Down, Replacement/Adjustment,

 7-39

Outrigger, Replacement, 7-43

PTO Adapter, Replacement, 3-3

Pump

Arctic Kit Water, Replacement, 21-6

Auxiliary Hand, Repair, 18-9

Main Hydraulic Driveshaft Repair, 20-2
TM 9-2320-364-20-5

INDEX-10 

Subject, Para

Q

Quick Disconnect Assembly, Interface, Replacement,

21-12

Quick Release Valve Replacement, 12-39

R

Radiator Grille Assembly Replacement, 17-14

Radiator Replacement, 6-5

Rear

Bracket Assembly, CHU, Replacement, 21-32

Composite Light and Bracket Repair, 7-47

Fender and Fender Support Arm Replacement, 17-35

Fender Side Marker Light Replacement, 7-48

Guide, CHU, (SRW), Replacement, 21-39

Hard Lift Assembly Replacement, 15-8

Hard Lift Bracket Replacement, 15-11

Lock Limit Switch, CHU, Replacement/

 Adjustment, 21-26

Marker Light Assembly Repair, 7-53

Noise Panel Replacement, 17-29

Noise Panel Rubber Replacement, 17-30

Roller Assembly Replacement, 15-17

Splash Guard (Mud Flap)/Reflector/Spring Bar

 Replacement, 17-39

Support, Machine Gun Ring, Replacement, 22-3

Rectifier Replacement, 7-19

Reflector

Replacement, 19-2

Rear Splash Guard (Mud Flap)/Spring Bar

 Replacement, 17-39

Regulator

Air, Air Manifold/Pressure Protection Valve

 Assembly, Repair, 12-38

Voltage, Adjustment, (145 AMP), 7-7

Voltage, Replacement, (145 AMP), 7-6

Voltage, Replacement, (200 AMP), 7-8

Relay Replacement, 7-95

Relay Spring

Valve No. 1 Replacement, 12-16

Valve No. 2 Replacement, 12-17

Relays, Arctic Kit, Replacement, 21-2

Repair Parts, 2-3

Reporting Equipment Improvement Recommendations

 (EIR), 1-5

Remote Control Box, Crane, Repair, 18-4

Remote Engine Oil Filter Manifold Replacement, 3-9

Subject, Para

R (CONT).

Remote Engine Oil Filter Replacement, 3-7

Request Switch and Bracket, DDEC III 

Diagnostic, Replacement, 7-28

Reservoir

Air Dryer, Replacement, 12-35

Air No. 1, Replacement, 12-27

Air No. 2, Replacement, 12-28

Air No. 3, Replacement, 12-29

Air No. 4, Replacement, 12-30

Air No. 5, Replacement, 12-31

Hydraulic, Filler Breather Replacement, 20-14

Hydraulic, Strainer Replacement, 20-13

Main Hydraulic, Filter Assembly Replacement,

 20-10

Main Hydraulic, Replacement, 20-12

Main Hydraulic, Service, 20-11

Steering Hydraulic, Repair, 14-15

Windshield Washer, and Bracket Repair, 19-8

Resistor, Electric, Replacement, 7-96

Retainer Bar/Roller Replacement, 18-6

Reverse Alarm Replacement, 7-86

Reverse Light Repair, 7-50

Rifle Stowage Brackets Replacement, 17-57

Right

Fender Front and Rear Skirt Replacement, 17-33

Front Mud Flap Replacement, 17-37

Hand Baffle Replacement, 17-18

Left and Rear Grille Skins Replacement, 17-15

Rocker Cover and Gasket Replacement, 3-5

Side Noise Panel Replacement, 17-26

Ring, Machine Gun, Replacement, 22-2

Ring, Tie Down Replacement 15-13

Rocker

Cover and Gasket, Left, Replacement, 3-4

Cover and Gasket, Right, Replacement, 3-5

Switch Replacement, 7-27

Roller

Angled, Replacement, 15-16

Horizontal, Replacement, 15-15

Rear, Assembly, Replacement, 15-17

Retainer Bar/, Replacement, 18-6

Roof Cover Plate Replacement, 17-25

Rotary Paddle, and Air Cylinder, CHU, Replacement/

Adjustment, 21-43

Rubber Fender Edging Replacement, 17-32
TM 9-2320-364-20-5

 INDEX-11

Subject, Para

S

7-Pin Electrical Connector Replacement, 7-103

Safe Lowering Button Replacement, 7-41

Scope, 1-1

Seat Belt Replacement, 17-44

Seat, Cab, Repair, 17-40

Secondary Fuel Filter

Head Replacement, 4-14

Replacement, 4-13

Self-Adjuster, Brake Shoe/, Repair, 12-2

Self-Guided Coupler Repair, 15-20

Self-Recovery Winch (SRW)

Cable Replacement, 18-17

CHU, Rear Guide Replacement, 21-39

Front Guide Replacement, 18-14

Front Tension Guide Repair, 18-13

Rear Guide Replacement, 18-16

Rear Tension Guide Repair, 18-15

Replacement, 18-12

Troubleshooting, 2-30

Sending Unit

Engine Oil Pressure, Replacement, 7-79

Fuel Level, Replacement, 4-11

Transfer Case, Replacement, 7-82

Water Temperature, /Temperature Switch

 Replacement, 7-80

Oil Temperature, Transmission, Replacement, 7-81

Sensing Plate, CHU Proximity Switch and, (Hookarm

Up), Replacement/Adjustment, 21-24

Sensor

Coolant Temperature Sensor Replacement,

 DDEC III, 7-69

DDEC Turbo Boost, Replacement, 7-63

DDEC II Engine Oil Pressure, Replacement, 7-67

DDEC III Engine Oil Pressure, Replacement, 7-68

Fuel Temperature, Replacement, 7-62

Oil Temperature, Replacement, DDEC, 7-70

STE/ICE Engine Oil Temperature, Replacement, 7-66

STE/ICE Water Temperature, Replacement, 7-64

Throttle, Replacement, 7-58

Water Temperature Gage/Fan Control, 

 Replacement, 7-65

Subject, Para

S (CONT).

Separator, 

and Bracket, Fuel/Water, Replacement, 4-16

Filter, Fuel/Water, Replacement, 4-17

Fuel/Water, Service, 4-15

Service Before Operation, 2-6

Service Gladhand Bracket Replacement, 15-14

Service Relay Valve

No. 1, Replacement, 12-13

No. 2, Replacement, 12-14

No. 3, Replacement, 12-15

Shaft

Axle No. 5 Steering, Repair, 14-10

Gear Box Steering, Repair, 14-9

Steering Column, Replacement, 14-8

Shift Assembly, Transfer Case, Replacement, 9-4

Shift Selector, Transmission, Repair, 8-2

Shock Absorber

 and Bushing Replacement, 16-2

 Mounts Replacement, 16-3

Shocks, Springs and, Introduction, 16-1

Short Strut and Pin Bracket Assembly, CHU, 

Repair, 21-30

Shunt, Battery Box and, Repair, 7-89

Shut-off Valve, Fuel, Replacement, 4-10

Side Cab Grab Handle Replacement, 17-52

Sight Glass, Coolant Level, Replacement, 6-6

Skid Plate

Crossmember Replacement, 15-4

Replacement, 15-2

Structure Replacement, 15-3

Skins, Right, Left and Rear Grille, Replacement, 17-15

Skirt

Air Cleaner, Replacement, 17-16

Cooling, Replacement, 17-17

Left Fender Front and Rear, Replacement, 17-34

Right Fender Front and Rear, Replacement, 17-33

Slave Connector and Cable Replacement, 7-99

Slider Arm Assembly, CHU, Repair, 21-31

Slider/Pivot Assembly, CHU, Repair, 21-29

Solenoid 

Fan Control, Valve Repair, 20-5

Four Position Valve Replacement, 12-40
TM 9-2320-364-20-5

INDEX-12 

Subject, Para

S (CONT).

Spare Tire Carrier

and Davit Replacement, 15-21

Winch Replacement, 15-22

Wire Rope Replacement, 15-23

Special Purpose Kits Maintenance, Introduction, 21-1

Special Tools, TMDE, and Support Equipment, 2-2

Speedometer Replacement, 7-17

Spindle, Axle No. 1, 2 and 5 Pivot and, Inspection, 11-4

Spring Bar, Rear Splash Guard (Mud Flap)/Reflector 

 Replacement, 17-39

Spring Brake Valve Replacement, 12-18

Springs and Shocks Introduction, 16-1

STE/ICE Engine Oil Temperature Sensor 

Replacement, 7-66

STE/ICE Water Temperature Sensor Replacement, 7-64

STE/ICE-R Toggle Switch Replacement, 7-29

Start Aid, Ether, Assembly, Replacement, 4-18

Starter Motor Replacement, 7-12

Steering

Column and Bracket Replacement, 14-6

Column Shaft, Replacement, 14-8

Filter Adapter Head Replacement, 14-17

Filter Replacement, 14-16

Gear Torquing, Front, Procedure, 14-18

Hydraulic Hoses and Fittings Replacement, 14-14

Hydraulic Reservoir Repair, 14-15

Lock Replacement, 14-7

Shaft, Axle No. 5, Repair, 14-10

Shaft, Gear Box, Repair, 14-9

Stop Bolt Replacement, 11-10

System Maintenance, Introduction, 14-1

System Service, 14-2

System Troubleshooting, 2-32

Toe-in Adjustment, 14-3

Wheel Replacement, 14-5

Step, Cab Replacement, 15-5

Storage Maintenance Procedures, 2-50

Stowage Box

and Bracket Replacement, 17-54

Crane, Repair, 17-55

/Engine Cover Latch Adjustment, 17-60

Stow Cone Weldment, CHU, Replacement, 21-44

Stow Weldment, CHU, Replacement, 21-34

Strainer, Hydraulic Reservoir, Replacement, 20-13

Subject, Para

S (CONT).

Sunvisor Replacement, 17-45

Support Brackets, CHU Front, Replacement, 21-46

Support, Cab Seat, Replacement, 17-42

Support, CHU Bumper Weldment, Replacement, 21-41

Support, Ladder, Repair, 17-58

Suspension System Troubleshooting, 2-34

Switch Wiring Harness, Instrument Panel, 

Replacement, 7-15

Switch

12V Magnetic, Replacement, 7-92

24V Magnetic, Replacement, 7-94

24V Side Panel Magnetic, Replacement, 7-93

Arctic Pump, Replacement, 21-3

Battery Disconnect, Box Repair, 7-106

Brake Pressure, Replacement, 12-5

DDEC III Diagnostic Request, and Bracket

 Replacement, 7-28

Differential Pressure, Replacement, 7-84

Emergency Steering, Replacement, 7-105

Engine Oil Pressure, Replacement, 7-60

Engine, Replacement, 7-32

Ether Start Aid, Replacement, 7-33

Hand Brake, Replacement, 12-8

Hazard, Replacement, 7-35

Hydraulic Selector, Replacement, 7-31

Low Air, Replacement, 12-6

Outrigger Proximity, Replacement, 7-43

Mode, CHU, Replacement/Adjustment, 21-25

Parking Brake, Replacement, 12-7

Proximity, (Hookarm Down), Replacement/

 Adjustment, 7-37

Proximity, and Sensing Plate (Hookarm Up), 

 CHU, Replacement/Adjustement, 21-24

Proximity, (Hookarm Up), Replacement/

 Adjustment, 7-38

Proximity, (Mainframe Down), Replacement/

 Adjustment, 7-39

Rocker, Replacement, 7-27

STE/ICE-R Toggle, Replacement, 7-29

Thumbwheel Rheostat, Replacement, 7-26

Transfer Case Lockup, Replacement, 7-30

Transfer Case Neutral Start, Replacement, 7-83

Turbo Boost Pressure, Replacement, 7-61

Turbo Throttle, Replacement/Adjustment, 7-59

Turn Signal, Replacement, 7-35
TM 9-2320-364-20-5

 INDEX-13

Subject, Para

T

12-Pin Electrical Connector Replacement, 7-104

12 Volt Magnetic Switch Replacement, 7-92

24 Volt

Magnetic Switch Replacement, 7-94

Side Panel Magnetic Switch Replacement, 7-93

200 AMP Alternator Belts Replacement/Adjustment,

7-5

200 AMP Alternator Replacement, 7-3

200 AMP Voltage Regulator Replacement, 7-8

Tachometer

Drive Assembly Replacement, 7-73

Replacement, 7-20

Temperature Sensor DDEC Oil, Replacement, 7-70

Temperature Sensor DDEC III Coolant,

Replacement, 7-69

Thermostat

Ether Start Aid, Replacement, 4-20

Replacement, 6-7

Threaded Screw Insert Replacement, 17-59

Throttle

Position Control Replacement, 7-98

Sensor Replacement, 7-58

Turbo, Switch Replacement/Adjustment, 7-59

Thumbwheel Rheostat Switch Replacement, 7-26

Tie Down Ring Replacement, 15-13

Tie-Rod and Drag Link Inspection, 14-12

Tie-Rod, Axle No. 1, 2 and 5, Repair, 14-11

Tire Carrier

Spare, and Davit, Replacement, 15-21

Spare, Winch, Replacement, 15-22

Spare, Wire Rope Replacement, 15-23

Tire Repair, 13-12

Tire, Wheel/, Assembly Repair, 13-2

Toe-in, Steering, Adjustment, 14-3

Tractor Protection Valve Replacement, 12-45

Transducer

Air Box Pressure, Replacement, 7-77

Air Cleaner Pressure, Replacement, 7-75

Fuel Filter Pressure, Replacement, 7-78

Fuel Pressure, Replacement, 7-74

Turbocharger Outlet Pressure, Replacement, 7-76

Transfer Case

Breather Replacement, 9-8

Differential Air Chamber Replacement, 9-3

Hose Replacement, 9-7

Lockup Switch Replacement, 7-30

Subject, Para

T (CONT).

Transfer Case (continued)

Maintenance Introduction, 9-1

Neutral Start Switch, Replacement, 7-83

Sending Unit, Replacement, 7-82

Service, 9-2

Shift Assembly Replacement, 9-4

Shift Cable Adjustment, 9-5

Shift Cable Replacement, 9-6

Troubleshooting, 2-22

Transmission

Breather Replacement/Service, 8-5

ECU Replacement, 7-71

Hose, Engine/, Replacement, 3-10

Introduction, 8-1

Oil Filter (External) Replacement, 8-4

Oil Service, 8-3

Oil Temperature Sending Unit, Replacement, 7-81

Shift Selector Repair, 8-2

Troubleshooting, 2-21

Tread Platform Assembly, Auxiliary Fuel Tank,

Replacement, 15-24

Tread Platform Assembly Replacement, 15-9

Treadle Valve, Brake, Replacement, 12-4

Troubleshooting

Air System, 2-27

Arctic Pump, 2-36

ATEC, 2-15

Axle, 2-33

Axle No. 3 Air Bag, 2-25

Brake System, 2-24

Central Tire Inflation System (CTIS), 2-26

Container Handling Unit (CHU), 2-38

Cooling System, 2-18

Crane, 2-29

DDEC II, 2-13

DDEC III, Appendix H

Driveshaft, 2-23

Electrical System, 2-20

Engine, 2-16

Exhaust System, 2-19

Fuel System, 2-17

Hydraulic System, 2-31

Instructions, 2-11

Interface, 2-37

Introduction, 2-10

Introduction to Logic Tree, 2-25
TM 9-2320-364-20-5

INDEX-14 

Subject, Para

T (CONT).

Troubleshooting (continued)

Load Handling System (LHS), 2-28

Steering System, 2-32

Suspension System, 2-34

Transfer Case, 2-22

Transmission, 2-21

Wheels and Tires, 2-35

Winch, 2-30

Truck-to-Trailer LHS Electrical Connector Bracket

 Replacement, 15-19

Tubing, Heater/Defroster, Replacement, 19-19

Turbo Boost Pressure Switch Replacement, 7-61

Turbocharger Outlet Pressure Transducer 

Replacement, 7-76

Turbo Throttle Switch Replacement/Adjustment, 7-59

Turn Signal Switch/Hazard Switch Replacement, 7-35

U

Univeral Joints, Driveshaft and, Repair, 10-2

Unpacking and Deprocessing, 2-4

V

Valve

Air, CHU, Replacement, 21-42

Brake Treadle, Replacement, 12-4

CTIS Wheel, Replacement, 13-11

Dash Manifold, Replacement, 12-37

Fan Control Solenoid, Repair, 20-5

Hand Brake, Replacement, 12-46

Heater Control, Replacement, 19-18

Interface Auxiliary Hydraulic, Replacement, 21-17

Interface Manual Override Solenoid, Replacement,

 21-18

No. 1, Relay Spring, Replacement, 12-16

No. 1, Service Relay, Replacement, 12-13

No. 2, Relay Spring, Replacement, 12-17

No. 2, Service Relay, Replacement, 12-14

No. 3, Service Relay, Replacement, 12-15

Quick Release, Replacement, 12-39

Solenoid Four Position, Replacement, 12-40

Tractor Protection, Replacement, 12-45

Vernier Control Replacement, 7-100

Voltage Regulator Adjustment, (145 AMP), 7-7

Voltage Regulator Replacement, (145 AMP), 7-6

Voltage Regulator Replacement, (200 AMP), 7-8

Subject, Para

W

Warning

Buzzer Replacement, 7-25

Lamp Replacement, 7-24

Warranty Information, 1-6

Water Pump, Arctic Kit, Replacement, 21-6

Water Temperature

Gage/Fan Control Sensors Replacement, 7-65

Sending Unit/Temperature Switch 

 Replacement, 7-80

STE/ICE, Sensor, Replacement, 7-64

Waterjacket, Arctic Kit, Replacement, 21-7

Weight Classification Sign Replacement, 19-21

Weldment

CHU Deck, Replacement, 21-40

CHU Stow Cone, Replacement, 21-44

CHU Stow, Replacement, 21-34

Support, CHU Bumper, Replacement, 21-41

Wheel

/Tire Assembly Repair, 13-2

and Tire Maintenance Introduction, 13-1

and Tires Troubleshooting, 2-35

Steering, Replacement, 14-5

Valve, CTIS, Replacement, 13-11

Winch

Crane, LHS Maintenance Introduction, 18-1

Self-Recovery, Replacement, 18-12

Spare Tire Carrier, Replacement, 15-22

Troubleshooting, 2-30

Window

Guard Replacement, 17-46

Peep, Replacement, 17-31

Windshield

Washer Cab Air Regulator Replacement, 12-26

Washer Reservoir and Bracket Repair, 19-8

Wiper Idler Shaft Replacement, 19-7

Wiper Motor Replacement, 19-4

Wiper

Arm Replacement, 19-5

Blade Replacement, 19-6

Wire Harness

Arctic Kit, Replacement, 21-8

Arctic Kit Switch, Replacement, 21-10

CHU, Replacement, 21-20

Engine Brake, Replacement, 7-102

General, Repair, 7-101
TM 9-2320-364-20-5

 INDEX-15/(INDEX-16 blank)

Subject, Para

W (CONT).

Wire Rope, Spare Tire Carrier, Replacement, 15-23

Wiring

Battery Box, Replacement, (145 AMP), 7-90

Battery Box, Replacement, (200 AMP), 7-91

CHU Control Box, Replacement, 21-22

Harness, Instrument Panel Gage, Replacement, 7-14

Harness, Instrument Panel Switch, Replacement,

 7-15

Work Lamp, Hand Held, Assembly, Repair, 7-55

 SCHMTC-1/(SCHMTC-2 blank)

SCHEMATICS

The following sections contain the schematics which are the same in all volumes of TM 9-2320-364-20 and

TM 9-2320-364-34.

Section I contains the schematics for trucks equipped with the 145 amp alternator and the DDEC II engine.

Section II contains the schematics for trucks equipped with the 200 amp alternator and the DDEC III engine.

 SCHMTC-3/(SCHMTC-4 blank)

SCHEMATICS

Section I. 145 AMP ALTERNATOR AND DDEC II ENGINE.

Section I contains the schematics for trucks equipped with the 145 amp alternator and the DDEC II engine.




































 SCHMTC-5/(SCHMTC-6 blank)

SCHEMATICS

Section II. 200 AMP ALTERNATOR AND DDEC III ENGINE.

Section II contains the schematics for trucks equipped with the 200 amp alternator and the DDEC III engine.



























TM 9-2320-364-20 Date of TM Title of TM

Date you filled out this form

Enter your mailing address
Commander

U.S. Army Tank-automotive and Armaments Command

ATTN: AMSTA-AC-NML

Rock Island, IL 61299-7630
TM 9-2320-364-20 Palletized Load System

Unit Maintenance Manual
Commander

U.S. Army Tank-automotive and Armaments Command

ATTN: AMSTA-AC-NML

Rock Island, IL 61299-7630
TM 9-2320-364-20 Palletized Load System

Unit Maintenance Manual
Commander

U.S. Army Tank-automotive and Armaments Command

ATTN: AMSTA-AC-NML

Rock Island, IL 61299-7630
TM 9-2320-364-20 Palletized Load System

Unit Maintenance Manual
Commander

U.S. Army Tank-automotive and Armaments Command

ATTN: AMSTA-AC-NML

Rock Island, IL 61299-7630
DENNIS J. REIMER

General, United States Army

Chief of Staff

JOEL B. HUDSON

Administrative Assistant to the

Secretary of the Army

9911901

iU.S. GOVERNMENT PRINTING OFFICE: 1997 545–010/60527

By Order of the Secretary of the Army:

Official:

DISTRIBUTION:

To be distributed in accordance with the initial distribution number (IDN) 380898, 

requirements for TM 9-2320-364-20-5.


PIN: 077309-000